hot work

Hot Work
Any activity that involves open

flame, spark or heat is known as
hot work.
• Hazards of Hot Work:
•
• Fire and Explosion
• Welding fumes and dusts
• Skin and eye burn from the sparks
or flame
• Heat stress specially in summer
season
• Infrared or UV radiation from the
welding arc
• Electrocution
• Noise
• Flying particles
• Trip over trailing cables
• Physical injury from grinders and
other tools
•
Controls of Hot • Documents:
• Area:
Work ( Safety • Equipment:
Precaution ) • People:
Area:
1. Remove all the combustibles and heavy oil deposits from the area and contain the sparks with fire blanket
- 8 meters
2. All the valves, drains and canals where possible flammables should be covered - 15m radius
3. Frequent Gas testing should be done - 15m radius
4. Barricade the area and put signage
5. Wet the area with water and pressurized fire water hose should be kept near the hot work area.
6. Certified and valid fire extinguisher should be there
Equipment:
1. Welding machine should be 3rd party certified GFCI (Ground Fault Circuit Interrupter):
2. GFCI or ELCB should be there ELCB (Earth Leakage Circuit Breaker):
3. Grounding of the welding machine
4. All cables must be properly double insulated
People:
1. Fire watcher must be present

2. Welder should wear fire resistant leader PPEs )Safety Helmet, hand gloves, Apron), face shield
3. Clean the area after job done
• Welding Machine Inspection:
• Grounding/Earthling
• TPC (third party certificate)
• ELCB (Earth Leakage Circuit
Breaker)
• Emergency STOP Button
• Drip Tray
• Spark arrester (1 year validity)
• Fire extinguisher
• Welding fumes consist number of hazardous
gases such as:
•
• Nitrous Oxide (Oxides of Nitrogen, NOx).
• Carbon dioxide (CO2).
• Carbon monoxide (CO).
• Shielding gas (e.g., Argon gas used in
welding).
• Ozone (O3).
•
•For All Equipment
• Cable
• GFCI
• Inspection Sticker
• Color Code
• Damage
Gas Cylinders:
Gas cylinders shall be color coded

1. Standard hose (BS 5120) that is used to connect torch to gas cylinder shall be
kept as short as possible.
2. Hose shall be in good working condition and should be color coded
3. Hose check valve (non-return valves), which allows gases to
blowpipe but not back from it, shall be fitted to each hose at
the torch.
4. Flash back arrester (restricts the back flow of gases into the
equipment or supply line and stops the flame) must be
installed in both oxygen and fuel gas lines.
5. Storage compounds should have 2 means of exit and storage
area should be properly ventilated.
Flash back arrester
A flashback arrestor is a special gas safety device most commonly used in oxy-fuel welding and
cutting to stop the flame or reverse flow of gas back up into the equipment or supply line and it
prevents the user and equipment from damage or explosions.
1. Cut-off valve shall also be incorporated for
automatically shutting of the gas supply.
2. Store cylinders at cool well ventilated and
dry area away from the combustibles
3. Segregate empty and full cylinders
4. Store cylinders at designated area
5. with chains
6. Store cylinders upright with valve outlet
seals and valve protection caps
7. Use cylinder cage and cradle to lift a cylinder
8. Proper hand truck or cart must be used to move cylinders.
9. Do not drag the cylinders.
 Store cylinders at least 30m from hot

work location and combustible
materials in a dry, ventilated place.
 Keep oxygen cylinders at least 20 feet
from fuel gas cylinders.
Fire is a chemical reaction caused by heat, fuel, and
oxygen.
•Combustible: A material that can catch fire and burn but requires a higher temperature to ignite (more
than 37 TEMP) Examples: wood, paper,.
•Flammable: A material that catches fire easily and burns quickly at lower temperatures.(less then 37
TEMP) Examples: gasoline, alcohol, and Gases.
Fire classification
•Class A: Ordinary combustibles (wood, paper, cloth).
•Class B: Flammable liquids & gases (gasoline, oil, paint).
•Class C: Electrical equipment (wiring, appliances, circuit breakers).
•Class D: Combustible metals (magnesium, sodium).
•Class F/K: Cooking (kitchen )oils and fats (specific to kitchen

Methods for extinguishing the fire:
There are three main methods to extinguish a fire. These involves removing one of the essential elements of fire (Fuel,
Heat and Oxygen):
1. Cooling - removal of Heat (by water generally for class A fire)

2. Smothering - removal of Oxygen (by using CO2 or DCP)
3. Starvation - removal of Fuel (by cutting fuel supply)
Fire Extinguisher Type Classifications of Fire
Water Extinguisher Class A
Foam Extinguisher Class A, Class B
Dry Chemical Extinguisher Class A, Class B, Class C
Carbon Dioxide (CO2) Class B, Class C
Class F (or Class K in

Wet Chemical Extinguisher
ANSI/OSHA)
A Fire Watchman is a designated person responsible for monitoring and ensuring fire safety,
especially during high-risk activities like hot work (welding, grinding, cutting) or in areas prone to
fire hazardsan
authorized and trained person who are watching for hazards and controlling fire in hot work
activity .
The Fire Watchman plays a critical role in preventing fires and ensuring the safety of workers and facilities.
Responsibilities of a Fire Watchman:
1.Monitor Hot Work Activities:
•Keep a close watch during welding, grinding, cutting, or other activities that produce sparks or heat.
2.Identify Fire Hazards:
•Check for flammable materials, gases, and fire-prone conditions in the area before and during the activity.
3.Maintain Fire Safety Equipment:
•Ensure fire extinguishers, fire blankets, and other firefighting tools are available and functional.
4.Extinguish Fires:
•Act immediately to extinguish small fires using appropriate firefighting equipment.
5.Stay Alert Post-Work:
•Remain in the area for at least 30-60 minutes after hot work to ensure no residual sparks ignite a fire.
6.Raise the Alarm:
•Notify emergency personnel immediately in case of fire or unsafe conditions.
7.Ensure Safety Compliance:
•Verify that all fire safety precautions, such as permits and control measures, are in place.
8.Clear the Area:
•Ensure non-essential personnel and flammable materials are safely removed from the hot work area.

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Hot Work

Any activity that involves open

1. Fire watcher must be present

Gas cylinders shall be color coded

 Store cylinders at least 30m from hot

•Class B: Flammable liquids & gases (gasoline, oil, paint).

•Class C: Electrical equipment (wiring, appliances, circuit breakers).

•Class D: Combustible metals (magnesium, sodium).

•Class F/K: Cooking (kitchen )oils and fats (specific to kitchen

1. Cooling - removal of Heat (by water generally for class A fire)

Water Extinguisher Class A

Foam Extinguisher Class A, Class B

Dry Chemical Extinguisher Class A, Class B, Class C

Carbon Dioxide (CO2) Class B, Class C

Class F (or Class K in

Responsibilities of a Fire Watchman:

1.Monitor Hot Work Activities:

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