1. Hot Work Safety Training Welding, Cutting, & Brazing

2. Scope
This program applies to ALL employees and contractors at the facility. The Hot Work Program contains the minimum requirements needed to safely perform hot work.
Since every situation is different, no one checklist will cover all precautions needed.
Therefore, it is essential that management, employees, mechanics and contractors study the situation in detail, plan the course of action applying all reasonable precautions and execute the job safely.

3. Statement of Policy
It is the policy of Nestle to eliminate the need for Hot Work.
In cases where this is not feasible, all precautions shall be taken to conduct the Hot Work in a manner that does not constitute a general hazard or fire/explosion hazard.

4. Responsibilities Area Supervisor
visually inspect the entire area (35 ft radius) where the Hot Work is to be performed and assure that the surrounding thirty-five (35) feet is clear of ALL flammable and combustible material or covered/protected by fire blankets if not able to be moved
approve the permit by signing in the appropriate location;

5. Responsibilities Area Supervisor
ensure the fire watch understands their responsibilities and that they are trained in the use of fire extinguishers and summoning emergency help;
ensure that any contractors performing Hot Work have received training on site Hot Work procedures and understand their responsibilities under the permit.

6. Responsibilities Person Doing the Job
ensure that the surrounding thirty-five (35) feet is clear and REMAINS clear of all flammable and combustible material or covered/protected by fire blankets if material is stationary
ensure that all Hot Work is performed safely and within the scope of the approved permit.

7. Responsibilities Person doing the job-
follow all steps in the procedure(s) / permit;
be constantly aware of his/her surrounding conditions;
shutdown Hot Work operations when ANY of the permit conditions change.

8. Responsibilities Fire Watch-
relieve themselves of ALL operational duties and monitors Hot Work area for fires;
is trained on the proper use of the fire extinguishing media available;
is trained in the means to summon help should an emergency situation arise;
remains in the area for thirty (30) minutes after the Hot Work is completed to monitor for fire;
signs off on the permit at the end of the thirty minutes;

9. Definitions
Hot Work - any work that may generate a source of ignition.
TYPE 1 HOTWORK - Any use of an OPEN FLAME or VISIBLE SPARKS such as welding, cutting, grinding, any visible spark producing work, etc.
TYPE 2 HOTWORK - NO open flame - Use of electrical equipment/tools, air activated tools, opening an electrical panel in a LEVEL 1 area, sandblasting, band saws, impact wrenches, conduit threaders, jack hammers, sump pumps, portable engines, any high temperature producing equipment, TIG welding, and Soldering, etc.

10. Definitions
Fire Watch- any employee, which has been trained in the use of a fire extinguisher within the past year, been trained in the facilities/methods to be used to sound an alarm in the event of a fire, has been relieved of ALL operational duties in order to observe the Hot Work for fire prevention, and remains at the site for 30 minutes after the completion of Hot Work.
Flammable liquids- any liquid which has a flash point below 100F or has been heated to within 30F of its flash point.

11. Definitions
Hazardous Hot Work Atmosphere- any atmosphere with a concentration greater than 0% LEL, 22.0% of oxygen, and visibly dusty environments.

12. Hot Work Safety Procedures
PERMITS:
Hot Work permits will be issued during normal business hours; however, permits may be issued and/or carried over during off shift hours.
Permits written or carried over during these off shift hours should be held to as few as possible due to the limited support available in the event of an emergency.
The individual that has issued the permit(s) must be present within the plant during the duration of the permit.

13. Hot Work Safety Procedures
PERMITS:
If the approver of a Hot Work permit must leave the plant site, he/she is responsible for either CLOSING the permit(s) that he/she approved or having someone relieve them of this status.
The relief person for the permit(s) MUST approve the permit(s) BEFORE the original approver leaves the plant site.

14. Hot Work Safety Procedures
PERMITS:
A permit will be required when a piece of equipment that has contained flammable or combustible materials is transported from an operating area to one of the shops and any Hot Work is performed on it.
Hot Work done in the DESIGNATED maintenance and weld shops can be done ONLY when the area is free of combustibles and flammables and a charged/inspected fire extinguisher is present.

15. Hot Work Safety Procedures
WARNING!
A worker performing Hot Work in an area that has been designated safe for Hot Work without a permit, is not relieved of their responsibilities for ensuring that the area is safe for Hot Work.
The following conditions must be maintained in these areas:
1) no combustibles or flammables within 35 feet and
2) an inspected, charged, 10 pound ABC extinguisher is present.

16. Hot Work Safety Procedures
PERMITS:
Permits will only be issued immediately before the work is to be performed.
Any jobs that are delayed or interrupted for more than 20 minutes will require a re-inspection.

17. Hot Work Safety Procedures
PERMITS:
WARNING! No permit will be issued before an inspection of the area is conducted by the approving personnel to insure all safety precautions have been taken, the work has been discussed with the employee(s) in the area and the work is deemed safe by all effected employees.
Approving authorities, employees and mechanics may recommend additional reasonable precautions.

18. Hot Work Safety Procedures
PERMITS:
Only trained Approval personnel may issue Hot Work permits.
Any conditions required on the permit that can NOT be met, requires the Plant Manager’s approval and signature on that Permit.

19. Hot Work Safety Procedures
Hot Work SAFETY REQUIREMENTS:
The Hot Work Permit MUST be approved by the Dept. Supervisor.
A Fire Watch is required while all Hot Work is in progress and 30 minutes after Hot Work has been completed.
ALL wall and floor openings must be covered with fire blankets to prevent sparks from penetrating adjacent areas.
ALL combustibles and flammables will be moved to a minimum of 35 feet from the Hot Work to be performed. If not possible, the combustibles and flammables will be protected by either : 1) covered by a fire blanket and/or 2) by wetting down the surrounding thirty-five (35) feet.

20. Hot Work Safety Procedures
Hot Work SAFETY REQUIREMENTS:
CAUTION! When an area has been wet down, personnel must be protected from possible shock.

21. Hot Work Safety Procedures
Hot Work SAFETY REQUIREMENTS:
Prior to Hot Work, ALL U-drains, sumps, duct work, dikes and conveyor systems in the 35 ft. vicinity of work will be emptied, cleaned, and all openings will be covered with a fire proof tarp.
Any sprinkler and or fixed extinguishing system(s) in the area MUST be operational.

22. Hot Work Safety Procedures
Hot Work SAFETY REQUIREMENTS:
Hot Work will NOT commence until an LEL of 0-1% is reached and O2 is less than 22.0%.
An adequate means of fire extinguishment (10 lb. ABC minimum) will be on hand at all times during ALL Hot Work.
NOTE: Permanently mounted extinguishers are NOT to be used as Fire Watch extinguishers!

23. Hot Work Safety Procedures
Hot Work SAFETY REQUIREMENTS:
Hot Work of any TYPE will NOT be done on equipment containing a flammable material (Flash Point <100F) or a material within 30 F of its flash point until the equipment is emptied, cleaned, properly prepared and it’s atmosphere is at 0-1% LEL and oxygen is less than 22.0%.

24. GENERAL SAFETY GUIDELINES
Arc welding will be conducted in an enclosed booth wherever possible.
Welding shields will be used at all times to protect workers in the area from the glare of welding and prevention of ignition of walls, partitions, ceilings, or roof of combustible construction. Shields will be at least one (1) foot off the ground to allow adequate ventilation.
All precautions will be taken for protection from metal fumes. Ventilation and/or the appropriate respirators will be used when working with metals containing zinc, lead, cadmium, beryllium, mercury and flurochlorine compounds.
NOTE: If the space is less than 10,000 cubic feet per welder or the ceiling height less than 16 feet in height, mechanical ventilation is required.

25. PERMIT ISSUANCE & CLOSURE
The “person doing the job” is responsible for completing the permit.
The area supervisor assures that the proper steps have been taken to allow safe work.
After the area preparations are complete, the area supervisor approves the permit by signing it.

26. PERMIT ISSUANCE & CLOSURE
The person who approves the permit must be the department supervisor (or the qualified designee such as a process engineer or department manager when he/she is off site).
The key is that the person who approves the permit must be fully knowledgeable of the status of operations in the area at that time.
The approved Hot Work permit must be posted at the work site.

27. PERMIT ISSUANCE & CLOSURE
The issued Hot Work permit is VOID if ANY ONE of the following conditions occurs.
Plant emergency alarm
Area or plant evacuation (caused by weather or other circumstances)
The permit time expires
If work does not commence within twenty (20) minutes of the permit being issued.
The Department Supervisor or Approval personnel for that permit leaves the plant site and a replacement is not found.

28. PERMIT ISSUANCE & CLOSURE
If area conditions change and create a potential hazard or the nature of the Hot Work chan­ges that deviates from the already approved permit (i.e., requiring tools that are not listed in the permit).
If the fire watch, or any other employee, shuts the job down because of unsafe prac­ti­ces, acts, or conditions.

29. PERMIT ISSUANCE & CLOSURE
Cancellation of the Hot Work permit:
The maximum authorized duration is one production shift.
The original permit may be used to approve the work for the next shift if this is needed. To do this the permit MUST be re-approved by the original or new department supervisor if the permit is to extend beyond the original shift.
NO permits are ALLOWED to continue for a period longer than 24 hours, EVEN with approvals at each shift change!!!!

30. PERMIT ISSUANCE & CLOSURE
Cancellation of the Hot Work permit:
After the Hot Work task has been completed, the fire watch is to patrol the area for 30 minutes, looking for any conditions that may result in a fire.
At the end of the 30 minutes, the fire watch will then sign off on the permit, stating the time of day and give the Hot Work permit to the department supervisor.
The Department Supervisor/Approval Authority closes the permit by conducting a final inspection of the Hot Work site.
The permits are sent to the EHS Department by the area supervisor. The EHS Department maintains the closed permits for one (1) year.

31. Personal Protective Equipment
Helmets or hand shields with the proper tinting must be used when arc welding/cutting.
PPE must be in good condition, nonflammable, made of material which is an insulator for heat and electricity.
Confined Space Entry Attendants, fire watches, or helpers need same PPE if exposed to the same hazards.
Goggles or suitable eye protection must be used in conditions which necessitate.
Respirators meeting NIOSH or MSHA specifications are required where ventilation is not sufficient.
Long sleeves for everyone on job.
Welding Gloves for welders.

32. Confined Spaces Hoses not being used must be removed from the space.
If welding or cutting is performed in a confined space and work is suspended, electrodes must be removed from their holders, torch valves closed and gas supply shut off and torch removed from the vessel during the suspended time. No unused torch or hoses will remain in a confined space.
Heavy portable equipment must be chocked and outside of space.
Gas cylinders must be fastened down outside of the space.
WARNING! NEVER use oxygen to ventilate the space!

33. Hot Work Permit

34. Hot Work Safety Reference Documents Questions?
29 CFR , .253, .254, .255, and ANSI/AWS F4.1-88
Questions?