ONLINE self-study

1. ONLINE self-study UNC Hot Work Permit Program Safety Training

2. Course Objectives • 1) Be able to identify the general hazards associated with Hot Work Activities • 2) Be able to explain the procedures involved in the • UNC Hot Work Permitting System. • 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.

3. 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.

4. Hot Work Definitions Hot Work Definitions

5. 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.

6. Hot Work Definitions 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.

7. Hot Work Definitions 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.

8. Hot Work Definitions • 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.

9. Hot Work Definitions 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.

10. Hot Work Definitions 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.

11. Hot Work Definitions 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.

12. Hot Work Definitions 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

13. Hot Work Definitions 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

14. Hot Work Definitions 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.

15. Hot Work Hazards Hot Work Hazards

16. Hot Work Hazards Fire Hazard: Molten metal, sparks, slag, and hot work surfaces can cause fire or explosion if precautionary measures are not followed.

17. 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.

18. 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: • Floors, partitions, and roofs • Wood, paper, textiles, plastics, chemicals, and flammable liquids and gases, and dusts. • Ground cover such as grass and brush.

19. 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

20. 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.

21. Hot Work Hazards Can you Identify Some of the Hazards in the following Illustrations?

22. Hot Work Hazards What Hazards Exist in the below illustrations?

23. 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.

24. Hot Work Hazards What Hazards Exist in the below illustration?

25. 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.

26. 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.

27. Hot Work Permit Program Requirements; Hot Work Locations

28. Hot Work Permit Program Requirements- Hot Work Locations • Hot work is allowed in two types of locations: • 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. • 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.

29. Hot Work Permit Program Requirements- Hot Work Locations 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.

30. Hot Work Permit Program Requirements- Hot Work Locations 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.

31. Hot Work Permit Program Requirements- Hot Work Locations 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.

32. Hot Work Permit Program Requirements- Hot Work Locations 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.

33. Hot Work Permit Program Requirements- Hot Work Locations Non- Permissible Area(s)/Location: Hot work shall not be permitted in the following areas: • In areas not authorized by Management. • In sprinklered buildings where sprinklers are impaired. • In the presence of explosive atmospheres (i.e., where mixtures of flammable gases, vapors, liquids, or dust with air exist). • 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. • In areas with an accumulation of combustible dusts that could develop explosive atmospheres.

34. Hot Work Permit Program Requirements Hot work is prohibited: • In, on, or near tanks, vessels, or containers that contain or have contained flammable substances.

35. Hot Work Permit Program Requirements- 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:

36. Hot Work Permit Program Requirements- 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:

37. Hot Work Permit Program Requirements- 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:

38. Hot Work Permit Program Requirements- Hot Work Location Examples Non- Permissible Area(s)/Location Examples:

39. Hot Work Permit Program Requirements Non- Permissible Area(s)/Location Examples: 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.

40. Hot Work Permit Program Requirements

41. Hot Work Permit Program Requirements Analyze the Hazards- Prior to initiation of hot work, perform a hazard assessment that identifies: • The scope of the work, • Potential hazards, • Methods of hazard control.

42. Hot Work Permit Program Requirements 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 AUTHORIZEDin a non-permissible location.

43. Hot Work Permit Program Requirements Here is an example of a decision flow that can be utilized to help determine if a hot work permit is needed or not.

44. Hot Work Permit Program Requirements 1. Is there an acceptable alternative to hot work?? YES NO YES NO YES YES YES NO YES NO Yes, Complete job with Cold Work. No hot work permit is needed.? Yes, Examine designated area, then complete hot work there. No hot work permit is needed.? 2. Can hot work be performed in a designated area (e.g. Maintenance Shop)? Yes, Obtain a written hot work permit.? 3. Is the proposed work to be performed in a non-designated area (e.g. NOT in a Maintenance Shop)?? • YES, Hot Work and Permit are Not Authorized in a non-permissible area 4. Is the proposed work to be performed in a non-permissible area? • No, Obtain a written hot work permit to work in a Controlled Area.

45. Hot Work Permit Program Requirements • 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.

46. Hot Work Permit Program Requirements • 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.

47. Hot Work Permit Program Requirements UNC Hot Work Permit: Click on the below Hot Work Permit

48. Hot Work Permit Program Requirements • 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.

49. Hot Work Permit Program Requirements 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.

50. Hot Work Permit Program Requirements 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.