Purpose The purpose of this safety program is to aid business owners with their Federal OSHA compliance efforts. Each business is unique and each program will require customization. As the program is customized, remember to only include words, sections, concepts, procedures, etc. that are relevant to the operations. The purpose of any written safety program is to provide a clear and consistent plan for addressing safety in a particular area of focus. Use Use this wizard to customize your program Instructions To develop your customized plan, follow steps 1 through 3 in order, by clicking the buttons and following the instructions prompted by the program. Customize Review and Format Approve & Save

<CompanyName>

Hot Work Program

Version <Version>

Updated: <Date>

Contents

1.	Program Purpose	1

2.	Definitions	1

3.	Responsibilities	1

4.	Guidelines/Procedures	2

5.	Training	9

6.	Recordkeeping	10

Appendix I: Hot Work Permit	11

Employee Acknowledgement	13

Program Purpose

The purpose of this program is to provide guidelines and requirements for conducting welding and cutting operations. This procedure applies to <CompanyName> employees conducting welding and cutting operations. It does not apply to work on or about processes of highly hazardous chemicals or work in confined spaces.

Definitions

Hot Work – any task or activity involving electric or gas welding, cutting, or brazing, or other work operations that produce sparks or use flames.

Hot Work Permit – a means of documenting that the fire prevention and protection requirements in 29 CFR 1910.252(a) have been implemented. Hot Work Permits are required when conducting hot work outside of designated areas and must be issued prior to commencing hot work.

Personal Protective Equipment (PPE) – equipment that, when selected and used properly, provides protection from a specific hazard and reduces an individual's exposure and risk of injury.

Welder or Welding Operator – any qualified operator of electric or gas welding and cutting equipment.

Responsibilities

<JobPosition1> has overall responsibility for the implementation and execution of this program including:

Updating this program, as necessary

Providing and/or verifying that employees are trained and qualified to conduct operations safely

Verifying that hot work operations are carried out in accordance with this program

<JobPosition2> will serve as the Permit Authorizing Individual (PAI). The PAI is responsible for:

Conducting initial training for hot work personnel and fire watch team, in addition to annual refresher training for fire extinguisher use

Training, as needed, when there are changes to employee responsibilities, hot work program protocols, or emergency response procedures

Assessing whether hot work is required or if an alternative method is available

Determining the controls and conditions required for the hot work being conducted

Confirming required controls and conditions are in place prior to authorizing hot work

Prohibiting hot work and denying authorization if required controls and conditions are not in place

Monitoring hot work activities to verify compliance with permit requirements

Maintaining completed hot work permits

Reviewing completed hot work permits periodically

All employees are responsible for observing the requirements of this program

Guidelines/Procedures

The following information provides guidelines/procedures and requirements for conducting hot work.

Designated Areas

A designated area is a location designed and/or approved for hot work. This may include maintenance shops, welding shops, or other locations that are constructed of noncombustible or fire-resistant materials, essentially free of combustible and flammable contents, and suitably segregated from other work areas. Designated areas are also typically equipped with ventilation systems to remove hazardous fumes, gases and dust that may be produced during hot work. Whenever possible, hot work operations will be conducted in designated areas.

Permit Required Areas

If the hot work cannot be moved to a designated area, a permit required area can be established providing that the area can be made fire safe. To conduct hot work in these areas, the following requirements in the next section must be met.

Work Area Preparation

Prior to issuance of a hot work permit or beginning hot work, permit required areas must be made fire safe. This includes but is not limited to:

Verifying the availability of appropriate, fully charged and operable fire extinguishing equipment in the hot work area

Removal of combustible materials to at least 35 feet (11 meters) from the hot work

Using metal or fire-retardant guards or curtains to protect/shield combustibles that cannot be removed

Wetting down or otherwise protecting floors constructed of combustible materials

Removal of flammable liquids

Tightly covering ducts and wall and floor openings within 35 feet (11 meters) of the hot work with fire-retardant or noncombustible material

Shutting down or tightly covering ducts or conveyor systems that may carry sparks to distant combustibles

Use of an explosion meter to verify % L.E.L. (Lower explosion limit)

Assignment of a Fire Watch

Use of other monitoring equipment to verify safe levels of hazardous fumes and/or gases (if applicable)

If hot work will be conducted on or near non-combustible partitions, walls, ceilings, or roofs, hot work personnel will confirm that areas adjacent to the opposite side of the partitions, walls, ceilings, or roofs are:

Free of flammable and combustible materials, or

Free of flammables are removed and combustibles are properly protected to prevent ignition

In addition, the work area must be properly secured to protect other personnel from hot work hazards (i.e., welding curtains, barricades).

Hot Work Permits

Hot work permits will be issued and authorized by the PAI or by the supervisor or manager having jurisdiction over the area where work is being performed if the PAI is not available. The permit must be posted in the work area or on the equipment being worked on. The permit must designate the type of hot work (i.e., burning or cutting, etc.), persons conducting the work, duration of work, and required controls and conditions. A separate permit is required for each work area and work group. Hot work permits are valid only for the work described and for no more than one work shift. Upon completion of the hot work, the permit must be returned to the PAI issuing supervisor or manager, who will maintain them for periodic review.

A hot work permit is provided in Appendix I.

Fire Watch

A fire watch is required for hot work conducted where more than a minor fire may develop or when any of the following exists:

Appreciable combustible materials, in building construction or contents, are closer than 35 feet (11 meters) to the point of operation.

Combustibles are more than 35 feet (11 meters) away but are easily ignited by sparks.

Wall or floor openings within a 35 feet (11 meters) radius expose combustible material in adjacent areas including concealed spaces in wall or floors.

Combustible materials are adjacent to the opposite side of metal partitions walls, ceilings, or roof and are likely to be ignited by conduction or radiation.

Additional fire watches are required if combustible materials that could be ignited by the hot work operation cannot be directly observed by one fire watch.

Fire watches will:

Be present during the hot work operation

Remain at the hot work site for at least 30 minutes after the hot work operation is completed

Verify that safe conditions are maintained during hot work operations

Be allowed to perform additional tasks only if those tasks do not interfere with fire watch duties

Have appropriate fire extinguishing equipment readily available

Watch for fires and/or smoldering in all exposed areas and:

Attempt to extinguish them only when the fires are obviously within the capacity of the equipment available, or

Activate the fire alarm immediately if the fire is beyond that capacity of available fire extinguishing equipment

Conduct monitoring as required

Fire watches will be trained in the:

Hazards of the work site and the hot work being conducted

Procedures to activate the fire alarm

Proper use of fire extinguishing equipment

Proper use of monitoring equipment (if applicable)

Prohibited Areas and Conditions

Hot work is prohibited:

When it is not authorized by <CompanyName> management

If the facility's sprinkler system is impaired

In an area with an explosive atmosphere

In areas where large quantities of readily ignitable material are stored

Hot Work Equipment

Welding and cutting equipment must be kept in safe operating condition. Equipment will be inspected and maintained in accordance with the manufacturer's recommendations and regulatory requirements. Equipment found to be damaged, defective, or otherwise incapable of reliable safe operation will be removed from service immediately and reported to management. The equipment will be repaired by <JobPosition3> prior to being returned to service or replaced, as appropriate.

Welding and Cutting

The following general safety guidelines are to be observed by employees when conducting welding and cutting operations:

Verify employees are thoroughly instructed in the safe use of welding equipment and fuel gas.

Conduct welding and cutting only in areas where adequate air flow is provided. If airflow in the work area is not adequate, mechanical ventilation must be provided in the form of either general mechanical ventilation systems or local exhaust systems. These systems must withdraw respirable air and exhaust to open air, or to an exhaust system.

Check the preservative coatings on the surface to be welded for flammability and toxicity. Remove a sufficient amount of preservative coating from the area to be heated to check that the temperature of the unstripped metal will not be appreciably raised. Artificial cooling of the metal surrounding the heating area may be used to limit the size of the area required to be cleaned. If the preservative coating contains substances which may affect a worker's health, the worker may have to wear a respirator if other exposure control methods are not feasible.

Place welding and cutting equipment (cylinders and/or welding machines) far enough away from the actual welding or cutting operation so that sparks, hot slag, or flame will not reach them. When this is impractical, the equipment must be protected.

Remove or protect any fire hazards, such as flammable (i.e. fuel gas and gasoline storage containers) or combustible (i.e. accumulations of airborne dust or on surfaces of paper clippings, wood shavings and textile fibers) materials in the work area. Cover wall or floor openings by which slag created from hot work operations may travel and/or accumulate.

Verify suitable fire extinguishing equipment is maintained in a state of readiness for instant use. Such equipment may consist of pails of water, buckets of sand, hose or portable extinguishers depending upon the nature and quantity of the combustible material exposed.

When operational safety needs require supplementary fire protection, additional personnel must be assigned to guard against fire in the form of a fire watch. Fire watches must be instructed as to the specific anticipated fire hazards and how the firefighting equipment provided is to be used. Fire watches must be present while the actual welding, cutting, or heating operation is being performed, and for a sufficient period of time after completion of the work to confirm that no possibility of fire exists.

Welding cables/hoses and other equipment will be kept clear from passageways, ladders, and stairways.

Welding, cutting, or other hot work must not be performed on used drums, barrels, tanks or other containers until they have been cleaned so thoroughly as to make absolutely certain that there are no flammable materials present or any substances such as greases, tars, acids, or other materials which when subjected to heat, might produce flammable or toxic vapors. Any pipe lines or connections to the drum or vessel must be disconnected or blanked.

Hollow spaces, cavities, and/or containers will be vented to allow for the release of pressure, air, and/or gases.

Personal Protective Equipment

Personal protective equipment (PPE) for welding operations includes but may not be limited to eye and face protection, gloves, and protective clothing. PPE requirements will be based on the type of welding performed, the task conducted, and the vicinity of the employee to the welding operation and will be provided to employees at no cost to them. PPE will meet applicable OSHA requirements and specifications, be in good condition, and be inspected, maintained, stored, and used in accordance with manufacturers' recommendations.

Eye and face protection is required for welders, welder assistants, and other employees who are exposed to eye and face hazards associated with welding operations. Eye and face PPE may consist of safety glasses, safety goggles, face shields, welding helmets, or some combination thereof. Light filtering lenses will be selected based on the welding operations being performed, as listed below:

Type of Welding Operation	Shade No.
Shielded metal-arc welding: 1/16-, 3/32-, 1/8-, 5/32-inch electrodes	10
Gas-shielded arc welding (nonferrous): 1/16-, 3/32-, 1/8-, 5/32-inch electrodes	11
Gas-shielded arc welding (ferrous): 1/16-, 3/32-, 1/8-, 5/32-inch electrodes	12
Shielded metal-arc welding: 3/16-, 7/32-, 1/4-inch electrodes 5/16-, 3/8-inch electrodes	12 14
Atomic hydrogen welding	10-14
Carbon arc welding	14
Soldering	2
Torch brazing	3 or 4
Light cutting, up to 1 inch	3 or 4
Medium cutting, 1 inch to 6 inches	4 or 5
Heavy cutting, 6 inches and over	5 or 6
Gas welding (light) up to 1/8 inch	4 or 5
Gas welding (medium) 1/8 inch to 1/2 inch	5 or 6
Gas welding (medium) 1/2 inch and over	6 or 8
*Note: In gas welding or oxygen cutting in which the torch produces a high yellow light, use a filter or lens that absorbs the yellow or sodium line in the visible light of the operation.

Welding gloves and/or protective clothing is required for employees exposed to sparks, heat, and other physical hazards associated with welding.

Oxygen-fuel Gas Welding and Cutting

The following safety guidelines are to be observed by employees when conducting oxygen-fuel gas welding and cutting operations:

Make sure fuel gas and oxygen manifolds are labeled (painted or on a sign permanently attached) with the name of the substance they contain in letters at least 1-inch high.

Verify fuel gas and oxygen hoses are easily distinguishable from each other and must not have more than one passage. The contrast may be made by different colors or by surface characteristics readily distinguishable by the sense of touch. Oxygen and fuel gas hoses must not be interchangeable.

Whenever practicable, arc welding and cutting operations must be shielded by noncombustible or flameproof screens which will protect employees and other persons working in the vicinity from the direct rays of the arc.

Confirm oxygen-fuel gas systems meet OSHA design standards.

Arc Welding and Cutting

The following safety guidelines are to be observed by employees when conducting arc welding and cutting operations:

Shield arc welding and cutting operations with noncombustible or flameproof screens to protect other persons in the vicinity from direct arc rays.

When electrode holders are to be left unattended, the electrodes must be removed and the holder must be placed or protected so that they cannot make electrical contact with employees or conducting objects.

All arc welding and cutting cables must be completely insulated and be capable of handling the maximum current requirements for the job. There must be no repairs or splices within 10 feet (3.048 meters) of the electrode holder, except where splices are insulated equal to the insulation of the cable. Defective cable must be repaired or replaced.

Arc welding and cutting cables must be of the completely insulated, flexible type, capable of handling the maximum current requirements of the work in progress, taking into account the duty cycle under which the arc welder or cutter is working.

Grounding of the welding machine frame must be checked. Special attention must be given to safety ground connections of portable machines.

Cables with damaged insulation or exposed bare conductors must be replaced.

Pipelines containing gases or flammable liquids, or conduits containing electrical circuits, must not be used as a ground return. For information on welding on natural gas pipelines, refer to 49 CFR Part 192.

Only cable free from repair or splices for a minimum distance of 10 feet from the cable end to which the electrode holder is connected must be used, except that cables with standard insulated connectors or with splices whose insulating quality is equal to that of the cable are permitted.

Confirm welding systems meet OSHA construction standards and all required precautions and support equipment readily available before conducting arc-welding or cutting.

If welding must be performed under unusual conditions, specialized equipment must be used. Examples of unusual conditions include but may not be limited to exposure to:

Unusually corrosive fumes

Steam or excessive humidity

Excessive oil vapor

Flammable gases

Abnormal vibration or shock

Excessive dust

Weather

Unusual seacoast or shipboard conditions

The following voltage limits must not be exceeded:

Alternating-current machines

Manual arc welding and cutting - 80 volts

Automatic (machine or mechanized) arc welding and cutting - 100 volts

Direct-current machines

Manual arc welding and cutting - 100 volts

Automatic (machine or mechanized) arc welding and cutting - 100 volts

When special welding and cutting processes require values of open circuit voltages higher than the above, means will be provided to prevent the operator from making accidental contact with the high voltage by adequate insulation or other means.

Resistance Welding

The hazards associated with this type of welding are similar to those of arc welding. As a result, safety guidelines established in the general and arc welding sections must be followed. The following guidelines are to be observed when conducting resistance welding operations:

All welders and cutters designated to use resistance welding equipment must have been properly instructed and judged competent to operate such equipment.

Controls of all automatic or air and hydraulic clamps must be arranged or guarded to prevent the operator from accidentally activating them. Movable holders must have sufficient clearance to prevent the shearing of fingers carelessly placed on the operating movable holder.

All press welding machine operations, where there is a possibility of the operator's fingers being under the point of operation, must be effectively guarded by the use of a device such as an electronic eye safety circuit, two hand controls or protection similar to that prescribed for punch press operation. All chains, gears, operating bus linkage, and belts must be protected by adequate guards, in accordance with the machine guarding section of this package and OSHA's machine guarding guidelines.

Ignition tubes used in resistance welding equipment must be equipped with a thermal protection switch.

All portable welding guns, transformers and related equipment that is suspended from overhead structures, eye beams, trolleys, etc. must be equipped with safety chains or cables. Safety chains or cables must be capable of supporting the total shock load in the event of failure of any component of the supporting system.

Two or more safety emergency stop buttons must be provided on all special multi-spot welding machines, including 2-post and 4-post weld presses. On large machines, four safety pins with plugs and receptacles (one in each corner) must be provided so that when safety pins are removed and inserted in the ram or platen, the press becomes inoperative.

All doors and access panels of all resistance welding machines and control panels must be kept locked and interlocked to prevent access to live portions of the equipment by unauthorized persons.

Resistance welding equipment and installations will meet the requirements of OSHA 29 CFR 1910.255.

Training

Employees who will not participate in hot work operations but may be exposed to the hazards associated with them will be trained on:

Health and safety issues and hazards related to hot work

PPE requirements

Facility/site emergency response procedures

Employees who will conduct or participate in hot work operations will receive training on:

Hazards of the work area/site

Health and safety issues and hazards related to hot work

Safe operation of equipment

Safe use of the process

Permit requirements

Emergency response procedures

Proper use of and reasons for required PPE and other protective equipment

<CompanyName> employees who supervise employees conducting hot work or oversee hot work operations will also be trained on these topics.

Employees who may be designated as fire watches will be trained on the above topics and also on:

Procedures to activate the fire/emergency alarm

Proper use of portable fire extinguishing equipment, in accordance with OSHA 1910.157(g):

To be conducted initially and at least annually thereafter

Including information on hazards involved with incipient stage fire fighting and the use of fire extinguishing equipment

Proper use of monitoring equipment (if applicable)

Employees should be retrained when there are changes to:

Employee responsibilities

The Hot Work Program

Emergency response procedures

Recordkeeping

The following records will be maintained:

Training

Hot Work Permits

Appendix I: Hot Work Permit

This permit is required for work operations involving open flames, welding, or producing heat or sparks that are conducted outside of designated hot work areas. This permit must be posted in the work area. It is valid only for one work shift. Upon completion of work, permits must be returned to the Permit Authorized Individual or Supervisor, and maintained for annual review.

Hot Work Permit

Date	Hot work by: (check one)	Employee(s)	Contractor
Name(s)	Signature(s)
Supervisor
Hot Work Operator(s)
Work Description
Work Area
Start Date & Time	End Date & Time
Area Preparation
For each item, initial if preparation is complete or “N/A” if not applicable.	Initial
Sprinkler system, and extinguishers in hot work area are in service and operational
Hot work equipment is in good working condition, in accordance with manufacturer’s specifications
Special permission has been obtained to conduct hot work on metal vessels or piping lined with rubber or plastic
Within 35 feet of hot work:
Floors constructed of combustible materials are wetted down or otherwise protected
Personnel protected from electric shock when floors are wet
Flammable liquids, dust, lint and oily deposits are removed
Other combustible materials are removed or protected with approved materials or shields
Floors are swept clean and trash removed
Explosive atmosphere is eliminated
Wall and floor openings are covered
Ducts and conveyors that may carry sparks are tightly covered, protected, or shut down
For hot work on partitions, walls, ceilings, or roofs:
Construction is non-combustible and without combustible coverings or insulation
Areas adjacent to the opposite side of partitions, walls, ceiling, or roofs are either: Free of flammable and combustible materials or Free of flammable materials and combustible materials are properly protected from ignition
For hot work on enclosed equipment:
Enclosed equipment is cleaned of all combustibles and purged of flammable liquid/vapor
Pressurized vessels, piping, and equipment are removed from service, isolated, and vented
Required Controls	Yes/No
Required PPE:
O2 and LEL will be monitored continuously
A properly trained and equipped Fire Watch is required during work and for a minimum of 30 minutes after hot work, including breaks. (Name of Fire Watch)
Emergency contact(s) and communication method
Other:
Hot Work Authorization
I verify that the work area has been examined, preparations completed, and required controls are in place. Permission is authorized to conduct this work as specified in this permit.
Name:	Signature:
Completion of Work
Upon completion of work, the Permit Authorized Individual or Supervisor must confirmed that:	Initial
The work area and adjacent areas to which fire, sparks or heat might have spread were inspected and no evidence of fire, sparks or heat were observed.

Employee Acknowledgement

I have received information on <CompanyName>’s Hot Work Program. By signing below, I agree to abide by the procedures in this document and bring to the attention of my supervisor any questions or concerns had.
Employee Name: _________________________________
Employee Signature: ______________________________
Date: __________________________________________