Office of Risk Management EHS 008 - Hot Works Program 1.0 Purpose Hot Work is defined as welding, cutting, soldering, brazing, grinding, and other forms of torch operations that will introduce sparks or open flame to a work area. Potential health, safety, and property hazards result from the fumes, gases, dust, sparks, hot metal and radiant energy produced during hot work operations. Furthermore, for the purpose of this program, work activities classified as non-fire causing work (defined in Section 3.0) must comply with the hot work procedures to ensure that the fire protection system will be deactivated during the work. The Hot Work program is intended to: Preserve the safety of the worker performing the hot work Ensure safety to all building occupants during hot work operations Prevent accidental activation of the building fire detection system Limit losses from accidental ignition of property All hot work activity requires a Hot Work Permit (Appendix A) be completed and issued by Environmental Health and Safety (EH&S) or Facilities & Services. 2.0 Scope This procedure applies to any Clarkson University employee or outside contractor who will be performing open flame or hot work. This includes but is not limited to campus maintenance, departmental construction, or outside contractor personnel. It covers all open flame or hot work conducted on any part of the Clarkson University property. 3.0 Definitions Arc welding is a welding process where similar materials are joined with a heating process caused by an electric arc. In the most common use, this process includes the use of a filler metal. Brazing is a process intended to permanently join two or more metals/materials together to form a single assembly by heating them in the presence of a filler metal that begins to melt above 450 C (840 F). Cutting is to separate metals by using any gas, electric arc or flammable, or combination thereof. Grinding is to crush, pulverize, or reduce to powder by friction, especially by rubbing between two hard surfaces. Revised 3/19/2003, 11/1/2010 Page 1
Hot work area is the area exposed to sparks, hot slag, radiant heat, or convective heat as a result of the hot work. Hot work equipment includes electric or gas welding or cutting equipment use for hot work. Hot work/ Open Flame is any process that will introduce intense heat, sparks, or open flame to a work area. Hot work activity includes but is not limited to, welding, thermit welding, cutting, burning, soldering, brazing, pipe thawing, grinding, thermal spraying, installation of torch-applied roof systems and other forms of torch operations. Hot work program is a permitted program, carried out by approved facilities-designated personnel, allowing them to oversee and issue permits for hot work conducted by their personnel or at their facility. The intent is to have trained, on-site, responsible personnel ensure that required hot work safety measures are taken to prevent fires and fire spread. Non-fire causing work is work which may interfere with fire protection systems but does not have the potential to start a fire. Some examples include dust generating work (e.g., sanding) or steam generating work. Non-torch operation is all other hot work operations other than defined Torch Operations. Normal business hours are Monday through Friday from 8:00 A.M. to 4:30 P.M., excluding College approved holidays (8:00 A.M. to 4:00 P.M. during the summer). Off business hours are all other times not defined as Normal Business Hours. Responsible person is a person trained in the safety and fire safety considerations concerned with hot work. Responsible for reviewing the sites prior to issuing permits as part of the hot work permit program and following up as the job progresses. Soldering is to unite (metallic surfaces or edges) by the intervention of a more fusible metal or metallic alloy applied when melted; to join by means of metallic cement. Torch-applied roof system is bituminous roofing systems using membranes that are adhered by heating with a torch and melting asphalt back coating instead of mopping hot asphalt for adhesion. Torch operation is a hot work operation where flammable gases are mixed with an oxidizer to create a flame (e.g., oxy-acetylene.) Welding is a process that joins metals by heating them to a melting point and allowing them to fuse or flow together, sometimes with an intermediate or filler metal having a high melting point. Revised 3/19/2003, 11/1/2010 Page 2
4.0 Responsibility 4.1 Environmental Health & Safety Assure an adequate Hot Work/Open Flame Program is established and implemented for Clarkson Facilities & Services employees and contracted vendors. Inform campus administrators who might hire outside contractors that these contractors are required to abide by the requirements of this program. 4.2 Facilities & Services Supervisors Provide hot work permits only to workers who have been properly trained as to the requirements of this program. Assure that the hot work/open flame area is properly protected. Assess the area for possible fire hazards (including hazardous and/or combustible materials). Insure a fire watch is assigned to hot works projects, where required. Authorize permits only when fire protection systems are not disabled. Schedule hot work jobs at times when it is less likely to impact combustible materials. Ensure that only approved equipment is designated for hot work activities. Stop hot work activities that do not have a proper permit on display and/or have not complied with all requirements of this program. 4.3 Project Managers When coordinating construction work, inform all contractors of this program. Require all affected personnel to comply with Hot Work/Open Flame standards. When coordinating construction work, inform all contractors of this program and ensure all contractors and subcontractors comply with this program. Work with contractor and supervisors in enforcing this policy. Stop hot work activities that do not have a proper permit on display and/or are not complying with all requirements or this program. 4.3 Employees Attend training on Hot Works procedures/policy. Obtain Hot Work permit before initiating hot work. Understand all fire prevention precautions, and how to use fire extinguishers, hoses, etc. Properly prepare area before performing hot work. Ensure that an impairment form is filled out if it is required. Contact electrician for disabling of smoke detector if needed. Be prepared to serve as a Fire Watch Observer or Fire Safety Coordinator during the period of the work. Use only approved equipment for hot work/open flame tasks. Report any equipment problems to your supervisor. Immediately inform supervisor of hot work activities with no permit posted Revised 3/19/2003, 11/1/2010 Page 3
4.4 Special note on responsibility (for all groups listed) This type of work has the potential for serious ramifications if the policy is not followed or enforced. Failure to comply with this procedure is a violation of work rules and may result in disciplinary actions. 5.0 Work Location and Equipment 5.1 Work Location and Safety Distances Whenever possible, hot work/open flame activities should be limited to controlled environments, such as a welding room or shop area, where the likelihood of fire is minimized. Areas like a welding room will not require a permit, but all personnel performing the work are to be trained and are expected to follow all applicable procedures. If the work cannot be moved, combustibles should be taken a safe distance away (at least 35 feet) or the combustibles must be properly shielded from ignition sources and the area should be swept clean. Where combustibles are not relocated, a fire watch on the opposite side from the work shall be provided. 5.2 Fixed Hot Work Areas Hot work activity will be allowed only in areas approved by supervisors. Fixed hot works areas, which do not need a hot works permit, include: Facilities Auto shop at Physical Plant Student Auto shop in Carpenter/Grounds Building HVAC Shop in Walker Welding shop at Physical Plant Welding Area in CAMP high bay A safe area radius of 35 feet (11 meters) will be established prior to initiating hot work if possible. All readily combustible materials shall be removed or covered with a protective blanket, floors shall be swept clean of wood shavings, paper clippings, textile materials, etc., and all cracks in walls, floors, or ducts covered to prevent sparks from passing through. When combustibles are within 35 feet, a fire watch will remain for 30 minutes after work stops. Any employee that may conduct hot work outside a fixed hot works area will be supplied with a fire extinguisher to be brought to the hot work site for use by the fire watch observer. 5.3 Cylinders and Other Equipment: Cylinders and other equipment must be managed as follows: Cylinders that are in use must be properly supported and placed a safe distance from torch operations. Revised 3/19/2003, 11/1/2010 Page 4
Cylinders must be labeled with the contractor name. All equipment must be in satisfactory operating condition. Cylinders must, when not in use, be properly supported and stored in a safe location protected from damage or exposure to fire. Oxygen and fuel gas cylinders and hoses will be located away from possibly being exposed to welding, cutting sparks, hot slag or hot metal. Remove all electrodes from holders during long breaks, place the holders well apart from each other, and disconnect power. Welding cables and other equipment must be placed so that it is clear of passageways, ladders, and stairways. 5.4 Surfaces with Combustible Coverings Welding is not to be attempted on a metal partition, wall, ceiling, or roof having a combustible covering, or on walls or partitions of combustible sandwich-type panel construction. If welding is to be performed on a metal wall, partition, ceiling, or roof, precautions must be taken to prevent ignition of combustibles on the other side, due to conduction or radiation (preferably by relocating combustibles). Where cutting or welding is performed near walls, partitions, ceilings, or roofs of combustible construction, fire-resistant shields or guards have been provided to prevent ignition. 5.5 Combustible Floors Combustible floors (except wood on concrete) must be kept wet, covered with damp sand, or protected by fire-resistant shields. Personnel operating arc welding or cutting equipment must be protected from possible electrical shock when floors are wetted. 5.6 Openings or Cracks in Surfaces in Hot Work Areas Openings or cracks in walls, floors, or ducts within 35 feet of the hot work area must be tightly covered to prevent the passage of sparks to adjacent areas. Conveyor systems that might carry sparks to distant combustibles must be protected. 5.7 Hot Work Areas with High Hazards Cutting or welding torches are not allowed in areas where there would be a high hazard, such as rooms containing flammable gases, vapors, liquids, dust or any other materials, which catch fire easily. 6.0 Hot Works Procedure 6.1 Fire Prevention and Precautions Revised 3/19/2003, 11/1/2010 Page 5
6.1.1 Fire Hazards. If the object to be welded or cut cannot readily be moved, all movable fire hazards in the vicinity shall be taken to a safe place. 6.1.2 Guards. If the object to be welded or cut cannot be moved and if all the fire hazards cannot be removed, then guards shall be used to confine the heat, sparks, and slag, and to protect the immovable fire hazards. 6.1.3 Restrictions. If the requirements stated in this section cannot be followed then welding and cutting shall not be performed. 6.2 Prohibited Areas Hot work shall only be conducted in areas designed or authorized for that purpose by the personnel responsible for a Hot Work Program. Hot work shall not be conducted in the following areas: In areas not authorized by management. In sprinkled buildings while such protection is impaired. In the presence of explosive atmosphere (mixtures of flammable gases, vapors, liquid, or dusts with air), or explosive atmospheres that may develop inside unclean or improperly prepared tanks or equipment which have previously contained such materials, or that may develop in areas with an accumulation of combustible dusts. In areas near the storage of large quantities of exposed, readily ignitable materials such as bulk sulfur, baled paper or cotton. 6.3 Obtain Hot Work Permit No hot work or open flame activity outside of specifically designated hot work areas is allowed without first obtaining a hot work permit. All persons engaged in hot works operations outside the fixed hot works areas must fill out a permit. This includes, but is not limited to Clarkson Facilities employees and outside contractors. Complete the Hot Works Permit Application in Appendix A. Permits may be granted for extended time, based on the project. However daily worksite checks, fire watches, and other requirements must be completed daily. Permits, however, are limited to one job site. 6.4 Gain Authorization Employees of the Physical Plant and contractors may obtain a Hot Works Permit from the Maintenance Supervisor, University Construction Clerk-of-the-Works, or Environmental Health & Safety Manager. This person will review the hot work to be done and check off all items under Safety Precautions in the Hot Works Permit that are applicable to the worksite. If it is safe, the Permit will be authorized with an expiration date and time. Revised 3/19/2003, 11/1/2010 Page 6
In some instances, fire-monitoring devices such as local smoke detectors must be deactivated in the immediate vicinity to prevent general alarms from sounding throughout the building. Any system deactivation or covering of smoke and/or head detectors must be noted on the Hot Work permit. Clarkson Facilities Supervisor or Clerk-of-the-Works must be notified of the deactiviation or smoke and/or heat detector covering. At the end of each day or at the completion of work, the alarm system must be re-activated and coverings removed. 6.5 Safety Precautions Check list Hot work equipment to be used must be in satisfactory operating condition and in good repair Combustible materials must be moved at least 35 feet away. All cracks and floor openings along with door and window openings covered. Exposed floors are kept clean and free from combustible material. No exposed combustibles are located on the opposite side of partitions, walls, ceilings or floors Fire Watchers shall have fire-extinguishing equipment readily available and be trained in its use. Fire Watchers are required, any time combustibles are closer than 35 feet to the point of welding or cutting being performed, and when walls and floor openings within a 35 foot radius expose combustible material in adjacent areas including concealed spaces in walls or floors. Fire watches must be continued for at least 30 minutes after completion of welding, cutting, or grinding operations to detect and extinguish possible smoldering fires. Visible hazard identification signs shall be provided where the hot work area is accessible to persons other than the operator of the hot work equipment. Conspicuous signs shall be posted to warn others before they enter the hot work area. A sample sign can be found in Appendix B. 6.6 Fire Extinguishers: Suitable fire extinguishing equipment shall be 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. An appropriate fire extinguisher is the preferred fire extinguishing equipment. 6.6 Fire Watch Firewatchers shall be required whenever welding or cutting is performed in locations where other than minor fires might develop, or any of the following conditions exist. Appreciable combustible material, in building construction or contents, closer than 35 ft to the point of operation. Appreciable combustibles are more than 35 ft away but easily ignited by sparks. Wall or floor openings within a 35 foot radius expose combustible material in adjacent areas including concealed spaces in walls or floors. Revised 3/19/2003, 11/1/2010 Page 7
Combustible materials are adjacent to the opposite side of metal partitions, walls, ceilings, or roofs and are likely to be ignited by conduction or radiation. 6.6.1 Fire Watch Requirements Fire Watchers shall have fire-extinguishing equipment readily available and be trained in its use. They shall be familiar with facilities for sounding an alarm in the event of a fire. They shall watch for fires in all exposed areas, try to extinguish them only when obviously within the capacity of the equipment available, or otherwise sound the alarm. A fire watch shall be maintained for at least a 30 minutes after completion of welding or cutting operations to detect and extinguish possible smoldering fires. Extra hot work precaution shall be exercised in the location of a sprinkler impairment. 7.0 Welding in Confined Spaces When employees perform welding or cutting in confined spaces (refer to the Clarkson University Confined Space Entry Program) the following safety provisions are required: Adequate ventilation must be assured All welding machines and gas cylinders must be kept outside the work space Wheels on portable equipment must be blocked to prevent accidental movement Torch valves must be closed and gas cylinders must be shut-off whenever the torch is inactive for a substantial period of time Torches and hoses must be removed from the confined space when not in use 8.0 Personal Protective Equipment Proper eye protection is required for each cutting and welding operation. Refer to Appendix C for an eye protection shade chart for use during welding. During all hot work operations, the worker must wear long sleeve shirts, pants, and have boots laced fully to the top. 8.1 Arc Welding or Cutting Operations Arc welding or cutting operations require helmets, hand shields, and appropriate clothing. Helmets must meet the following requirements: o Must insulate the operator from heat and electricity o Be non-flammable o Have filter plates and cover plates designed for easy removal o Be constructed of material that does not readily corrode or discolor the skin Revised 3/19/2003, 11/1/2010 Page 8
Hand shields must meet the following standards: o Must insulate the operator from heat and electricity o Be non-flammable The appropriate clothing must be worn. This includes, but is not limited to, long sleeve shirts, pants, and boots laced fully to the top are also required. A welding jacket or apron must also be worn. Welding jackets or aprons must meet the following standard: o Must insulate the operator from heat and electricity o Be non-flammable o Clothing must be free from holes 8.2 Gas Welding or Oxygen Cutting Operations Gas welding or oxygen cutting operations require goggles or other suitable eye protection. Goggles must meet the following standards: o Be non-flammable o Be capable of withstanding sterilization o Be ventilated to reduce fogging The appropriate clothing must be worn. This includes, but is not limited to, long sleeve shirts, pants, and boots laced fully to the top are also required. o Clothing must be free from holes 8.3 Gas Welding Operations on Light Work Gas welding operations on light work require spectacles with filter lenses without side shields. Eye protector lenses must meet the following standards: o Have essentially flawless tempered glass lenses o Unless the lenses are prescription lenses, the front and rear surfaces of lenses and windows must be smooth and parallel o Have lenses that are permanently marked to identify the source and shade that the lenses are designed to meet o Have all filter lenses and plates that meet the American National Standard Institute (ANSI) Standard for Practice for Occupational and Educational Eye and Face Protection, Z87.1-1998 8.4 Torch Brazing Torch brazing requires spectacles with filter lenses without side shields. See Eye protector lenses in Section 8.3 8.5 Brazing Brazing operations require suitable goggles. See Goggles in Section 8.2. Revised 3/19/2003, 11/1/2010 Page 9
9.0 Contract Work Contract employees under the supervision of Clarkson supervisors shall be required to follow all elements of this program. All contractors hired to work at any location on Clarkson property, and are under their own company supervision are required to comply all sections of this policy. Additional requirements of contractors working on Clarkson property are listed below. Hot work permits are required for roofing hot tar pots, and construction heating devices such as salamanders. Clarkson University reserves the right to cancel all permits due to an emergency, unplanned impairment, or non-adherence to the policy. 10.0 Training All personnel performing hot work must be trained in proper equipment operation, handling and storage of welding materials, compressed gas safety, chemical hazards, and the hot work program. Additional training may also be necessary in the proper selection and use of personal protective equipment. Training in confined space entry is necessary before working in such areas. Additional training is required for supervisors and clerkof-the-works prior to their issuing of permits. 11.0 Applicable Standards OSHA 1910.252 Welding, Cutting, and Brazing OSHA 1926.352 Fire Prevention NYS Fire Code Chapter 26 Welding and other Hot Work NFPA 51B Fire Prevention in Use of Cutting and Welding Processes Revised 3/19/2003, 11/1/2010 Page 10
APPENDIX A: HOT WORKS PERMIT GENERAL INFORMATION Hot Work Performed by: CU Employee Contractor Employee/Contractor Name: Contractor Company Name (if applicable): Date(s) of Hot Work Activity: Location (Building & Room): Time(s) of Hot Work Activity: Comment(s): TYPE OF HOT WORK ACTIVITY Arc Welding Soldering Grinding Brazing Cutting Non-Fire Work Other: Oxygen & Fuel Gas (check appropriate box): Welding Other information: Cutting YES NO NA SAFETY PRECAUTIONS Smoke/heat detectors disabled or covered. If yes, specify number and locations: Clarkson University personnel are notified of disabled fire detection system. Notification provided to: Date/time: Fire extinguisher on-site, fully charged and operable Floors cleared of readily combustible materials or shielded with fire retardant covers No explosive atmosphere present Flammable and combustible materials/chemicals removed or covered. All wall and floor openings are covered. Fire watch to be provided during and 30 minutes after working, including lunch and break times. Fire watch trained in use of and supplied with ABC fire extinguisher. Revised 3/19/2003, 11/1/2010 Page 11
I certify that the following safety precautions will be followed along with standard safety procedures for as long as the hot work is effective: All cylinders will be secured at all times. All cylinders will be in good, usable condition. All cylinders and fire extinguisher will be filled/charged/tested by authorized vendors only. Hot work equipment to be used must be in satisfactory operating condition and in good repair Combustible materials must be moved at least 35 feet away. All cracks and floor openings along with door and window openings covered. Exposed floors are kept clean and free from combustible material. No exposed combustibles are located on the opposite side of partitions, walls, ceilings or floors Fire Watchers shall have fire-extinguishing equipment readily available and be trained in its use. Fire Watchers are required, any time combustibles are closer than 35 feet to the point of welding or cutting being performed, and when walls and floor openings within a 35 foot radius expose combustible material in adjacent areas including concealed spaces in walls or floors. Fire watches should be continued for at least 30 minutes after completion of welding or cutting operations to detect and extinguish possible smoldering fires. Visible hazard identification signs shall be provided where the hot work area is accessible to persons other than the operator of the hot work equipment. Conspicuous signs shall be posted to warn others before they enter the hot work area. Employee Contractor Name: Signature: Date: CLARKSON OFFICIAL USE ONLY Authorizer Name: Issue Date: Issue Time: Authorizer Signature: Expire Date: Expire Time: Revised 3/19/2003, 11/1/2010 Page 12
APPENDIX B: HOT WORK WARNING SIGN CAUTION HOT WORK IN PROGRESS STAY CLEAR IN CASE OF AN EMERGENCY: CALL CAMPUS SAFETY & SECURITY x6666 Revised 3/19/2003, 11/1/2010 Page 13
APPENDIX C: SHADE CHART FOR EYE PROTECTION DURING WELDING Welding Operation Shade # Shade # 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 11 electrodes Gas-shielded arc welding (ferrous) 1/16-, 3/32-, 1/8-, 5/32-inch electrodes 12 Shielded arc welding: 3/16-, 7/32-, ¼-inch electrodes 12 Atomic hydrogen welding 14 Carbon arc welding 10-14 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 Heaving cutting, 6 inches and over 5 or 6 Gas welding (light) up to 1/8 inch 4 or 5 Gas welding (medium) 1/8 to ½ inch 5 or 6 Gas welding (heavy) ½ inch and over 6 or 8 Note: In gas welding or oxygen cutting where torch produces a high yellow light, it is desirable to use a filter or lens that absorbs the yellow or sodium line in the visible light of the operation. Revised 3/19/2003, 11/1/2010 Page 14