Hot Work Permit Program Safety Training by UNC

ONLINE SELF-STUDY
UNC Hot Work Permit Program Safety
Training

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.
3) 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.

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.

Hot Work Definitions
Hot WorkDefinitions

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

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.

Hot WorkOperatoris the Departmental
employee who is qualified and authorized by
management to perform hot work such as
welding, brazing, soldering, and other
associated work tasks.

 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.

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

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.

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

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

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

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.

Hot Work Hazards
Hot WorkHazards

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

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.

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

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

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.

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

Hot Work Hazards
What Hazards Exist in the below
illustrations?

Hot Work Hazards
What Hazards Exist?
 Eyehazards (UV optical radiation and burn hazards) to
the eyes.
 Skinburnhazards 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, andFall 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

Hot Work Hazards
What Hazards Exist in the below
illustration?

Hot Work Hazards
What hazards exist?
 Eyehazards: Impact hazards from flying chips
and debris, hot slag, and sparks.
 Inhalation(respiratory) hazards of dusts
generated when grinding on metal surface
coatings.
 Fire& IgnitionHazard(s) from flying sparks that
could ignite combustible materials in the work
area. Sparks can travel up to 35’ and ignite

Hot Work Hazards Summary
Hot workcan 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, orheat 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 worksafety practices is to avoid bringing
sparks, flame, or heat produced by the tool into contact with
a source of fuel.

Hot Work Permit Program Requirements;
Hot Work Locations

Hot Work Permit Program
Requirements- Hot Work Locations
 Hot work is allowed in two types of locations:
1) 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.
2) 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

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

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

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.

In a Controlled Area, a Hot WorkPermit 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.

Non- Permissible Area(s)/Location: Hot work shall not
be permitted in the following areas:
(1) In areas not authorized by Management.
(2) In sprinklered buildings where sprinklers are
impaired.
(3) In the presence of explosive atmospheres (i.e.,
where mixtures of flammable gases, vapors, liquids,
or dust with air exist).
(4) 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.
(5) In areas with an accumulation of combustible dusts
that could develop explosive atmospheres.

Requirements
Hot workis prohibited:
 In, on, or near tanks, vessels, or containers
that contain or have contained flammable
substances.

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:

Requirements- Hot Work Location
Examples
DIESEL FUEL
NO SMOKING
MATCHES OR
OPEN FLAMES
The University of North Carolina at Chapel Hill
Department of Environment, Health & Safety
1120 Estes Drive Ext., CB# 1650
Chapel Hill, North Carolina 27599

Requirements
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.

 Hot Work Permit Program Requirements

Requirements
Analyze the Hazards- Prior to initiation of hot
work, perform a hazard assessment that
identifies:
1) The scope of the work,
2) Potential hazards,
3) Methods of hazard control.

Requirements
After analyzing the hazards, see if there is any
possibility of Hot WorkAlternatives. 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 not required.
3) Is the proposed work to be performed in a non- permissible area?
HOT WORK AND PERMIT ARE NOT AUTHORIZED in a non-

Requirements
Here is an example of a decision flow that can be
utilized
to help determine if a hot workpermit is needed or
not.

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

Requirements
 If it is decided that a hot work permit is required
for a job task, the Hot WorkPermit 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.

Requirements
 The Hot WorkPermit 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.

Requirements
UNC Hot WorkPermit: Click on the below Hot
Work Permit

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.

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

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.

Requirements
Fuel sources (cont’d): If relocation is
impractical, combustibles shall be protected by
a approved welding curtain, welding blanket,
welding pad, or equivalent rated ANSI/FM
4950.

Requirements
Fuel sources (cont’d):
 If it is impractical to relocate combustibles, a
Fire Watch must be provided on the side
opposite from where work is being performed.

Requirements
A Fire Watch is needed when there is a chance
that fire might develop from combustible materials.
A fire watch is needed if combustible materials are
located:
1) Closer than 35’ from the hot work.
2) More than 35’ away from the hot work but
might be easily ignited by sparks.
3) Walls or floor openings within 35’ expose
combustible materials in adjacent areas including
concealed areas spaces in walls and floors.
4) Adjacent to the opposite side of partitions,

Requirements
The Fire Watch monitors the hot work area for
changing conditions and watches for fires, and
extinguishes them if possible. The Fire Watch
shall be familiar with the facilities and
procedures for sounding the fire alarm and
contacting the Fire Department in the event of
an emergency.
 Note: When changing conditions are observed
by anyone– whether the fire watch, hot work
operator, PAI, or any other employee– that
person should immediately halt the hot work on

Requirements
Remember, Fire Watches must:
1. Have fire extinguishing equipment readily available
and be trained in its use.
2. Be familiar with facilities for sounding an alarm and
contacting the Fire Department in the event of a
fire.
3. Watch for fires in all exposed areas.
4. Try to extinguish fires only when obviously within
the capability of equipment available, or otherwise
sound the alarm.
5. Be maintained for at least a half-hour after
completion of welding or cutting operations to
detect and extinguish possible smoldering fires.

Requirements
ContractorResponsibilities:
The designated departmental PAI should
supervise outside contractors that are planning
to engage in hot work activities.
The departmental PAI informs contractors
about site-specific hazards including the
presence of flammable materials at the work
site.

Requirements
Mutual Responsibility: Management,
contractors, the PAI, the fire watch, and the hot
work operators shall recognize their mutual
responsibility for safety in hot work operations.

Requirements
Individual Employee Responsibilities:
Any employee that observes changing unsafe
condition associated with hot work activities
must use individual initiative to report the
unsafe condition(s).
 Each employee has the right to halt hot work
operations when new conditions develop that
could pose a hazard to employees.
 An example of changing conditions might be
the introduction of a flammable substance into
the hot work area.

Hot Work Accident Case Studies

Case Study #1: 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

Case Study # 1: Explosion:
Previous Slide Photo & Below Information, Courtesy: U.S. CSB,
 Tanks involved in the 2006 accident that killed three workers . On
June 5, 2006, contract workers were installing a new pipe between two
oil tanks at a rural oilfield when sparks from a welding torch ignited
flammable hydrocarbon vapor venting from one of the tanks. That tank
and another nearby tank exploded, killing three workers who were
standing above the tanks and seriously injuring a fourth. All of the tanks
were interconnected by piping and one of the tanks contained crude oil,
the source of the vapor that fueled the explosions. The workers had not
performed combustible gas monitoring prior to or during the hot work
instead relying on the unsafe and unreliable practice of using a lit torch
to check one of the tanks for flammable vapor.
 Workers did not empty or isolate the tank that contained crude oil prior
to initiating hot work activities.
 Neither the contract company nor the parent company required written
hot work permits. The contractor company did not provide hot work

Hot Work Permit Program Case
Studies
Case Study # 2: Explosion: Below Information and Photo,
Courtesy: U.S. CSB,
A.V. Thomas Produce
Atwater, California, March 31, 2009
2 Workers Severely Burned
 Two employees at A.V. Thomas Produce were using an oxygen-acetylene torch to
loosen a fitting on an old fuel tank, which the company hoped to refurbish for field
storage of diesel fuel. The workers, however, were unaware that the tank contained
residual hydrocarbon liquid and vapor from an unknown prior use. The tank was not
cleaned or purged before work began. Shortly after applying heat to the tank, an
explosion occurred, blowing the end of the vessel off. Both employees were airlifted
to a regional burn center, where they were treated for burns covering 30 to 50% of
their bodies.
 The facility had no formal hot work program, and no permit was issued for the hot
work being performed. No combustible gas testing was performed prior to
commencement of the hot work; the company did not have a policy that required it.
In addition, many workers were mono-lingual Spanish speakers and had not been

Below Photo, Courtesy: U.S. CSB,
Exterior and interior views of the fuel tank
involved in the hot work accident at A.V.
Thomas Produce.

Below Information and Photo, Courtesy: U.S. CSB,
Bethune Point WastewaterPlant
Daytona Beach, Florida, January 11, 2006
2 Workers Killed, 1 Critically Injured
 Two workers were killed and another critically injured in an explosion
involving a methanol storage tank at a municipal wastewater treatment
facility in Daytona Beach, Florida. The explosion occurred while the three
workers were cutting a metal roof located directly above the tank vent.
Sparks showered from the cutting torch and ignited methanol vapor
escaping from the vent, creating a fireball on top of the tank. A corroded
and ineffective flame arrester15 on the vent allowed the fire to propagate
through the device, igniting methanol vapors and air inside the tank,
resulting in an explosion.
 Daytona Beach public employees were not covered by OSHA standards,
which is typical for local and state governments in a number of jurisdictions.
The city had no formal permitting system for hot work or non-routine
maintenance activities, and workers had not received any training on
methanol hazards in the previous 10 years. Combustible gas monitoring
was not performed or required.

Case Study #4: Fire at a University Library
 Courtesy: (NFPA 51Bstandard - Significant Hot Work
Incidents)
 University Library. Workers were using an acetylene torch to
remove old heating ducts in a utility shaft between the 20th
and
21st
stories of the tower of a 27-story university library building.
Flying sparks fell through a vent and ignited papers stacked
against the vent in a storage room on the 20th
floor. Apparently
the fire burned 20 to 30 minutes before discovery.
 There was no fire protection in the upper stories, except for
portable fire extinguishers, and fire fighters had to connect to the
standpipes in the 3rd
and 4th
stories and pull hose lines up the
enclosed stairways to the 20th
and 21st
stories. They finally
controlled the fire in 2.5 hrs, but damage extended to 4 stories
when fire spread by way of nonfirestopped utility shafts and
elevator shafts. The work was being done by two air-conditioning
installation workers, on contract. They had not investigated the
possibility of combustible material being in contact with the old

Case Study #5: Fire in Warehouse Facility
 Courtesy: (NFPA 51Bstandard - Significant Hot Work
Incidents)
 Warehouse Facility. While an arc welder was being used
on the second floor, sparks dropped through an opening to
cardboard boxes below and the boxes ignited. There was
no fire watch on the first floor, and when the fire was
discovered 15 minutes later, employees could not put it out.
They finally called the fire department but were too late to
save the two-story building of ordinary construction. The
total loss was $1.6 million.

Case Study #6:
 LumberMill. Workers had shut down one of several sprinkler
systems in the plant to remove branch lines to facilitate removal
of a conveyer. While workers were cutting bolts from the
conveyer with welding equipment, some of the sparks passed
through cracks in the floor and landed in sawdust accumulations
below. Smoldering occurred for 3 hours without being noticed by
the maintenance employees, who were the only people in the
plant. Meanwhile, the area in the region of the cutting
operations, but not the floor below, had been washed down and
visited regularly at ½-hour intervals.
 When the fire was finally noticed, some time was spent in trying
to extinguish it before the fire department was called. By the time
the fire department arrived, it was too late to save the lumber
storage and stacker buildings. Destruction caused a total loss of
$1.25 million.

Hot Work Permit Program Training Summary

Requirements- Summary
In Summary:
 Hot work activities creates various health and physical hazards. The goal of the hot
work permit program is to prevent heat sources from coming into contact with fuel
sources in order to prevent the possibility of fires and explosions that could result in
injury, death, and loss of property.
 Hot work is allowed in 2 types of locations. Designated area is a permanent
location (such as a Welding or Maintenance Shop) approved for routine hot work
operations. A Designated area has been made safe by removal of all possible
ignition sources.
 A Controlled Area is an out of shop location which safe conditions exist or where
safe conditions can be created by moving or protecting combustibles.
 A Hot Work Operator must obtain a Hot Work Permit from the Departmental Permit
Authorizing Individual before performing hot work in a Controlled Area.
 A Fire Watch must be posted when hot work is performed in a location where other
than a minor fire might develop.
 A Non-Permissible Location is a hazardous location such as a tank that holds
flammable chemicals. No Hot Work is allowed in this type of work environment.
 It is critical that proper planning and communication be implemented by all involved
in planning work involving hot work to reduce the possibility of injury, death, and

Conclusion
In conclusion, everyone involved with hot work
needs to understand and follow proper safety
procedures to prevent accidents associated with
hot work activities.

References Used and
Additional Hot Work Information
 REFERENCES:
 National Fire Protection Agency 51B, Standard for Fire Prevention during Welding,
Cutting and Other Hot Work.
 American National Standards Institute, Standard: Z49.1:2005, Safety in Welding,
Cutting, and Allied Processes
 US Chemical Safety Board: www.csb.gov
 American Welding Society, Safety and Health Fact Sheets
 OSHA General Industry Standard, Subpart Q, 1910.251- 1910. 255, Welding, Cutting,
and Brazing
 U.S. Army Corps of Engineers , Safety and Health Manual , Section 10 Welding and
Cutting
 Washington State Department of Labor and Industries, Hexavalent Chromium (chrome
6) Training on the hazards of hexavalent chromium in the workplace

Hot Work Permit Program Safety Training by UNC

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