Preventing Chemical Accidents: Hot Work

Preventing Chemical Accidents: Hot Work
Preventing Chemical Accidents

Hot Work
First Edition
Process Safety Management Training
from the
NJ Work Environment Concil
This material was produced under grant SH-171!-"-#"-$-!% &rom the 'ccupational Sa&et( and Health
Administration) *+S+ ,epartment o& -a.or+ /t does not necessaril( re0ect the views or policies o& the
*+S+ ,epartment o& -a.or) nor does mention o& trade names) commercial products) or organi1ations
impl( endorsement .( the *+S+ 2overnment+ This curriculum is revised &rom materials originall(
developed .( the *nited Steelworker3s Ton( 4a11occhi Center &or Sa&et() Health) and 5nvironmental
5ducation and produced .( the Steelworkers Charita.le and 5ducational 'rgani1ation) &unded in whole
or in part with &unds &rom the 'ccupational Sa&et( and Health Administration) *+S+ ,epartment o&
-a.or 6grant num.er SH-1##!7-"7-#"-$-%78+
i
Ta!le of Contents
A!ot WEC ii
Preventing Chemical Accidents iii
The Small "ro# Activity Method iv
The Factsheet $eading Method vi
Activity% Hot Work &
Task !
5valuation 1%
ii
A!ot WEC
The 9ew :erse( Work 5nvironment Council 6W5C8 is a non-pro;t
colla.oration o& organi1ations working &or sa&e) secure <o.s) and a
health() sustaina.le environment+
=isit W5C3s we.site at www+n<wec+org
For more information a!ot WEC #rograms and services'
contact%
>ick 5ngler) ,irector
9ew :erse( Work 5nvironment Council
1%7 West State Street - Third $loor) Trenton) 9: "#"-11"7
Telephone: 6#"?8 #?@-71""
$aA: 6#"?8 #?@-%7""
E(mail% info)n*+ec,org
iii
-ne.#ected releases o& highl( ha1ardous toAic) reactive) or
0amma.le chemicals create the possi.ilit( o& a disaster &or
workers) emplo(ers) and communities+
/SHA0s Process Safety Management Standard helps prevent
accidental releases o& highl( ha1ardous chemicals) thus protecting
emplo(ees) as well as plant neigh.ors+
E1ective +orker training a.out PS4 helps achieve sa&er)
healthier) and more productive workplaces+
/n 9ew :erse() PS4 regulates approximately 1"" &acilities)
including certain chemical plants) oil re;neries) &ood processors)
electric utilities) warehouses) and pu.lic and private sector water
and sewage treatment operations+ PS4 ma( also cover other
t(pes o& &acilities+ PS4 has special provisions &or contractors
working in covered &acilities+
WEC0s training crriclm covers ke( aspects o& the PS4
standard+ Training introduces the concept o& s(stems o& sa&et(
and accident prevention and wh( &acilities should esta.lish an
organi1ational structure to oversee PS4 implementation+ W5C
addresses 'SHA3s per&ormance-.ased reBuirements &or a plant
Cmechanical integrit(D program+ Training also covers accident)
incident) and near-miss investigations) &ocusing on root causes+
W5C also can provide training on related su.<ects) such as the
9ew :erse( Toxic Catastrophe Prevention Act 6TCPA8) emplo(er
and workerEunion rights to participate during 'SHA and TCPA
inspections) and development o& eFective la.or-management
sa&et( and health committees+
For more information' contact%
,enise Patel) PS4 'utreach Coordinator
W5C) 1%7 West State St) Third $loor
Trenton) 9: "#"
Call: 6#"?8 #?@-71"") 5Atension !"@
iv
$aA: 6#"?8 #?@-%7""
5-4ail: dpatelGn<wec+org
v
The Small "ro# Activity Method

2asic Strctre
The Small 2roup Activit( 4ethodH is .ased on a series o& pro.lem-
solving activities+ An activit( can take &rom %@ minutes to an hour+
5ach activit( has a common .asic structure:
I Small "ro# Tasks
I $e#ort(2ack
I Smmary
&, Small "ro# Tasks% The training alwa(s .egins with groups
working together at their ta.les+ 5ach activit( has a task) or set o&
tasks) &or the groups to work on+ The task asks that the groups
use their eAperience and the &actsheets to solve pro.lems and
make <udgments on ke( issues+
3, $e#ort(2ack% $or each task) the group selects a scri.e that
takes notes on the small group discussion and reports .ack to the
class as a whole+ ,uring the report-.ack) the scri.e in&orms the
entire class as to how his or her group solved the particular
pro.lem+ The trainer records each scri.e3s report-.ack on large
pads o& paper in &ront o& the class so that ever(one can re&er to
them+
4, Smmary% Je&ore the discussion dri&ts too &ar) the trainer
needs to .ring it all together during the summar(+ Here) the
trainer highlights the ke( points o& the activit( and .rings up an(
pro.lems or points that ma( have .een overlooked during the
report-.ack+
*The Small Group Activity Method (SGAM) is based on a training procedure developed by
ngland!s Trades "nion Congress (T"C) in the #$%&s' The (abor )nstitute and *il+ Chemical+
and Atomic ,or-ers "nion (no. part o/ the "nited Steel.or-ers) used a similar method
vi
around economic and health and sa/ety issues /or .or-ers and /urther developed the
procedure into SGAM' The 0e. 1ersey ,or- nvironment Council has used SGAM since
#$23'

Three 2asic 5earning E.changes
The Small 2roup Activit( 4ethod 6S2A48 is .ased on the idea that
ever( training is a place where learning is shared+ With S2A4)
learning is not a one-wa( street that runs &rom trainer to worker+
>ather S2A4 is a structured procedure that allows us to share
in&ormation+ /t is .ased on three learning eAchanges:
6 Worker(to(Worker
6 Worker(to(Trainer
6 Trainer(to(Worker
Worker(to(Worker% 4ost o& us learn .est &rom each other+ S2A4
is set up in such a wa( as to make the worker-to-worker eAchange
a ke( element o& the training+ The worker-to-worker eAchange
allows participants to learn &rom each other .( solving pro.lems
in their small groups+
Worker(to(Trainer% -ecture-st(le training assumes that the
trainer knows all the answers+ With S2A4 it is understood that the
trainers also have a lot to learn and this is the purpose o& the
worker-to-trainer eAchange+ /t occurs during the report-.ack and it
is designed to give the trainer an opportunit( to learn &rom the
participants+
Trainer(to(Worker% This is the trainer3s opportunit( to clear up
an( con&usion and make points the( think are ke(+ J( waiting until
the summar( section) trainers know .etter what people need to
know+
vii
The Factsheet $eading Method
The process descri.ed .elow &ocuses ever(one on the important
in&ormation in the &actsheets+
The process is as &ollows:
$irst) select a scri.e &or this Task+
5ach o& (ou will .e assigned a small num.er o& &actsheets to read+
Kou will then share the &actsheet in&ormation with (our ta.le+
Kour trainer will assign (our individual &actsheets this wa(:
Starting with the scri.e and moving to the le&t) count out loud
&rom 1 to + Leep going around the ta.le until all num.ers
6&actsheets8 are distri.uted+ The assigned num.ers correspond to
$actsheets 1 through on the &ollowing pages+
/nce everyone has read their assigned factsheets
individally' yor scri!e +ill go arond the ta!le and ask
each of yo to e.#lain to the gro# +hat yo have
learned, Factsheets shold !e e.#lained in the order
assigned 7& throgh 89' since the factsheets !ild on the
#revios one, :n this +ay' +e all start at the same #lace
and +ith the same information,
viii
Activity ;% Hot Work
Pr#ose
To understand and learn the elements o& a good hot work
program+
This Activit( has one task+
1
Scenario%
Art and >a( were sent to the Tank $arm to replace .earings on a
isopropanol pump located on the alcohol pad+ The( &ound the
.earings C&ro1enD in place+ When Art told his supervisor the(
would have to pull the pump) he said) C-et3s see i& we can3t pull
those .earings in placeM we3ve got too much downtime in that
area alread(+D $irst the( tried to loosen the .earings with a
.earing heater) a power&ul electric heat gun) without success+
>a( then called a welder who heated the casing with her torch
until the .earings came &ree+ While the welder was there) the
supervisor had her weld .rackets on an /-.eam so he could install
a CWarning-$lamma.le AreaD sign+
A piece o& slag &rom the welding rolled into a near.( pile o& damp
wooden shims+ A&ter the mechanics and the welder le&t the area)
the wood .egan to smolder and then .urst into 0ames+ At the
same time an operator .egan to charge ethanol to his unit .(
remote computer control+ The ethanol trans&er pump started to
leak around its mechanical seal creating a pool o& alcohol on the
pad+ The vapors &rom the pool traveled towards the ;re) which
then ignited them+
The ;re spread instantl( to the pump and grew in intensit( as the
heat increased the si1e o& the leak+ The tank &arm operator saw
the ;re) sounded the alarm and attacked the ;re with an
eAtinguisher+ She was overcome .( vapors and &ell unconscious+
Nuick response .( the in-plant emergenc( response team saved
her li&e and stopped a potentiall( disastrous ;re+
7
Task%
:n yor gro#s' choose a scri!e, <iscss the incident and'
!ased on yor e.#erience and factsheets & ( 8 on #ages =
( &3' ans+er the follo+ing >estions,
&, What cold have !een done to #revent this ?re@ 5ist
the factsheet7s9 yo sed to !ack # yor ans+er,
a8
.8
c8
d8
e8
3, No+' think a!ot the hot +ork #rogram in yor #lant'
are there any changes or im#rovements that shold !e
made to im#rove the #rogram@ Please list and e.#lain,
!
Factsheet A&
What :s Hot Work and Why :s :t HaBardos@
'SHA de;nes hot work as: Cwork involving electric or gas
welding) cutting) .ra1ing or similar 0ame or spark-producing
operations+D
We should .e concerned a.out hot work .ecause:
/n our plants a spark invites disaster .ecause o& the
tremendous potential &or 0amma.le vapors or gases to .e
present+
When we cut) weld or grind in our &acilities) literall(
thousands o& ignition sources in the &orm o& sparks and hot
slag are created+
Sparks and slag can scatter throughout an area where hot
work is going on O sometimes up to !@ &eet or more+
Sparks and slag can also pass through cracks) gratings)
doors) drains) open hatches and other openings in walls)
0oors or vessels) creating ;reEeAplosion ha1ards in
sometimes distant areas+
%
Source: 9$PA @1J C$ire Prevention in *se o& Cutting and Welding Processes)D 1??+
@
Factsheet A3
Hot Work May 2e More Than Co E.#ect
An(thing com.usti.le or 0amma.le can .e ignited .( hot work+
Welding) cutting and .ra1ing are prett( o.viousM .ut what a.out
those other C0ame or spark-producing operationsD that 'SHA
talks a.outP
2rinding) sanding and sand .lastingM
4etal-on-metal contact) metal-on-concrete contactM
/nternal com.ustion enginesM
5lectric tools) such as drills or sawsM
Cameras) .atter(-powered instruments) radios) etc+M and
5ven (our clothing can cause static sparks+
/& (our hot work permit s(stem does not address these sources) it
is not giving (ou the protection the law reBuires+
When (ou check out an area .e&ore doing hot work) it3s natural to
&ocus on the ha1ards o& the process 6solvent vapors) 0amma.le
gases and eAplosive dust-in-air miAtures) etc+8+ Jut waitM it3s eas(
to overlook other com.usti.le materials in a hot work area like
grass) de.ris) trash) pallets and ;.er drums+ /t pa(s to check the
area out thoroughl(+
Move itD
4ove com.usti.le materials at least !@ &eet &rom the hot work
area+ /& the( can3t .e moved) the( must at least .e protected
with 0ame-proo&ed covers or shielded with guards or curtains+
5dges o& covers at the 0oor should .e tight to prevent sparks &rom
going under them+ Com.usti.le 0ooring should .e wet down or
#
protected .( ;re-resistant shields+ Cover 0oor drains) trenches)
sewer .oAes) etc+
Source: 'SHA 1?1"+7@76a8M and 9$PA @1J C$ire Prevention in *se o& Cutting and Welding
Processes)D 1??+
Factsheet A4
Hot Work% Cor 5ast $esort
/n man( chemical plants and re;neries) it has .ecome routine to
do hot work in process areas O o&ten with the units still running+
The current trend in our industr( is to take the least amount o&
time possi.le to do maintenance work+ Planned shutdowns and
turnarounds &or maintenance are held much less &reBuentl( than
in the past+ 5ven when such work is scheduled) the length o& time
allowed is enough to take care o& onl( the most serious work
orders+
2t remem!er' it is almost al+ays safer to move that #iece
of e>i#ment ot of the #rocess area to a safe #lace
!efore doing hot +ork on it,
7
Source: Jased on interviews with &ormer 'CAW 69ow *SW8 mem.ers in the video) C'ut o&
Control)D produced .( the 'rgani1ing 4edia Pro<ect and availa.le &rom the ApeA Press) 9ew
Kork) 9K+

Factsheet A=
Where There0s Smoke There Shold 2e a Fire
WatchD
When hot work is .eing per&ormed the sparks 0( O literall(Q
Sparks produced .( hot work operations like grinding) cutting or
welding are o&ten spread over a large area+ This makes it
impossi.le &or grinders) welders or torch operators to do their
work and watch &or ;res too+ 'SHA sa(s a ;re watch must .e
assigned to the <o. i& there is a chance o& more than <ust a minor
;re+ /n our plants) no ;re is minor+ Consider the &ollowing real-li&e
eAamples:
>ouseville) PA: A welding operation on a stairwa( to a tank
was prepped and permitted in the morning+ The area was
gas-tested and &ound to .e clear o& an( -5- levels+ The
liBuid in the tank was not considered 0amma.le as it was a
miAture o& water and various products &rom the vacuum
truck recovered spills+ As the da( warmed up and conditions
changed) 0amma.le vapors &ormed and .egan rising oF the
tank+ The vapors were ignited and three contractors were
killed+
,elaware Cit() ,5: A welding operation was taking place on
a catwalk on a tank+ The work crew had .een repairing a
catwalk on a sul&uric acid storage tank when a spark &rom
their hot work ignited 0amma.le vapors in one o& the tanks+
This tank had holes in its roo& and shell due to corrosion+
The tank collapsed and one o& the contract workers was
killedM eight others were in<ured+
?
Factsheet AE
What0s a Fire Watch@
A ?re +atch is someone +ho , , , +ell , , , +atchesD
He or she continuousl( monitors the hot work area &or ;res that
ma( .e caused .( 0(ing sparks and an( changes in the
surrounding conditions that ma( make the hot work unsa&e+ The
ke( word here is continuousl(+ This is not a <o. to .e given to an
operator or mechanic who alread( has another <o. to do+
A ?re +atch is +ell trained,
$ire watches must .e trained in using ;re-eAtinguishing
eBuipment) including Chands onD practice with training ;res+ The(
must also .e trained in the &acilit(3s emergenc( procedures 6i+e+)
sounding an alarm) evacuation routes) etc+8 as outlined in the
plant3s written emergenc( response plan+
A ?re +atch kno+s +hat to do and +hen to do it,
/& a ;re occurs) the ;re watch must warn the hot work crew and
sound the plant alarm+ The ;re watch ma( tr( to eAtinguish a ;re
onl( when it is o.viousl( within the capacit( o& the ;re
eAtinguishing eBuipment availa.le and onl( i& the ;re watch has
.een properl( trained+
A ?re +atch mst cover all areas +here s#arks might
travel,
/& there are 0oor or wall openings) open ductwork) gratings) open
sewer drains or an( other wa( a spark ma( travel to another level
or area) more personnel need to .e assigned as ;re watches+
:t0s not over even +hen it0s over,
When the hot work ends) the ;re watch must continue &or at least
another !" minutes+H
1"
H'SHA 1?1"+7@7 6a8 6///8 6%8 68+
11
Factsheet A;
Hot Work Permits% No "arantee of Safety
A hot work permit is onl( as good as the in&ormation included on it
and the skills o& the person issuing it+ Several &actors have to .e
considered .e&ore issuing a permit:
E.#losive atmos#heres
Hot work o.viousl( can3t .e done near eAplosive atmospheres+
The area should .e checked with a com.usti.le gas anal(1er at
diFerent levels+ 5ven i& the air is clear) will it sta( that wa(P
Continuous monitoring should .e standard practice+
Near!y com!sti!les
4ove com.usti.le materials in the area !@ &eet &rom the hot work
area+ /& impractical) protect them with 0ame-proo& covers or
guards+
Fire #rotection e>i#ment
/nspect all ;re eBuipment and do not allow hot work in sprinklered
.uildings i& that protection is impaired+
Safe condition of srronding areas
/& something is going on near a hot work area that could create a
ha1ardous condition) those operations must .e made sa&e until
the hot work is ;nished+ /& there are 0oor openings) gratings) wall
openings or open ductwork or conve(ors that could allow sparks
&rom the hot work to .e carried into another area) the( must .e
covered or .locked+
17
Factsheet A; continued

Noti?cation of all #ersons involved
'perators on near.( units) supervisors) maintenance or other
workers near.( and contractors must .e aware o& the hot work
going on and o& the related ha1ards+ Posting a notice or sign is
recommended also+
Esta!lishment of a ?re +atch
/n addition) a hot work permit must include the date and time the
work is authori1ed and must identi&( the eBuipment to .e worked
on+ The permit must .e kept on ;le until the hot work operation is
completed+
>emem.er) i& the nature o& the <o. changes 6e+g+) another cra&t
.ecomes involved) new eBuipment is used or conditions
surrounding the <o. change8) a new hot work permit should .e
issued+
1!
Sources: 'SHA 1?1"+11?M and 9$PA @1J C$ire Prevention in *se o& Cutting and Welding
Processes)D 1??+
1%
Factsheet AF
Com!sti!le "as AnalyBers
How do (ou tell i& an area is clear o& 0amma.le gases or vaporsP
4ost plants use com.usti.le gas anal(1ers+ These are usuall(
small) hand-held units that test the air and give a reading
eApressed in percent lower eAplosion limit 6-5-8+ '&ten anal(1ers
&or oA(gen and other contaminants are com.ined in the same
unit+
Percent 5o+er E.#losion 5imit 75E59
$lamma.le gas will ignite onl( when the miAture o& gas and air is
in the right ratio+ Too little gas and the miAture is too lean to
.urn) too much gas and the miAture is too rich+
What concentration is safe@
Sa&et( concentrations are not speci;ed under 'SHA3s Process
Sa&et( 4anagement standard+ Jut 'SHA3s Con;ned Space
Standard speci;es a maAimum percent -5- o& 1" percent &or work
inside a con;ned space+ However) some plants will not do hot
work i& an( positive reading at all shows up on an anal(1er+
'thers use readings o& one percent or three percent o& the -5- as
their cut-oF point+
Ho+ often is enogh@
4ost plants onl( sample when the permit is issued+ A &ew repeat
the monitoring at regular time periods+ The .est protection is
oFered .( continuous monitoring+ This can .e done .( area
monitors with noticea.le alarms or .( eBuipping ;re watches
6a&ter proper training8 with anal(1ers during the hot work+
1@
Sources: 'SHA 1?1"+1%#M and 9ational Sa&et( Council) Accident Prevention Manual /or
4usiness and )ndustry) 1"th 5dition) /tasca) /-: The 9ational Sa&et( Council) 1??7+
1#
Factsheet A8
Monitoring the Monitors
4onitoring results are onl( as good as the eBuipment .eing used
and the training and eAperience o& those using it+ So .e sure that:
'nl( eAperienced) trained workers use a com.usti.le gas
monitor+
*nits have &ull( charged .atteries+
The anal(1er is intrinsicall( sa&e 6eAplosion proo&8+
*nits are cali.rated on a regular .asis and that cali.ration is
checked dail(+
And remem!er that%
4onitors will give &alse low readings i& the sample vapor is
ver( high in concentration+ /& the oA(gen level is low)
monitors will give &alse low readings o& 0amma.le vapors+
-iBuids or steam drawn into the unit will give &alse readings
and ma( damage the unit+ H(drogen will also aFect
readings+
4onitors do not give instantaneous readings+ The( reBuire
as long
as !" seconds to per&orm the anal(sis+ /& an auAiliar( pump
and tu.ing are used to sample a con;ned space or other
area) allow at least two more seconds per &oot o& sample
tu.ing &or the sample to reach the monitor+
/& the results o& an( anal(1er are suspect in an( wa() retest
with another unit immediatel(+
17
Some gases are heav() some aren3t+ Je sure testing is done
at several diFerent levels+
$or the most protection) insist on continuous monitoring+
Source: 9ational Sa&et( Council) Accident Prevention Manual /or 4usiness and )ndustry) 1"th
5dition) /tasca) /-: The 9ational Sa&et( Council) 1??7+
Smmary% Hot Work
1+ Hot work is an( <o. that can cause a ;re+
7+ The hot work permit is an important tool in the hot work
s(stemM .ut it
does not make unsa&e work sa&e+
!+ A permit must .e issued .e&ore the hot work .egins+ The
proper permit will record that sa&et( reBuirements have .een
met and the results o& the monitoring &or com.usti.les
6percent -5-8+
%+ The person authori1ed to issue a permit should check the area
o& the hot work &or:
5Aplosive atmospheresM
9ear.( com.usti.lesM
$ire protection eBuipmentM
Sa&e condition o& surrounding areasM
9oti;cation o& all persons involvedM and
5sta.lishment o& a ;re watch+
@+ The worker per&orming the hot work cannot do his <o. and
watch the area too+ At least one well-trained ;re watch should
.e posted in each hot work area+
1
#+ Hot work areas should alwa(s .e monitored &or 0amma.le
gases .e&ore hot work is per&ormed+ Jut the highest level o&
protection is given .( continuousl( monitoring the hot work
area+
7+ An( time (ou do hot work in a process area (ou take a risk+
Work like this should onl( .e a last resort+ >emove the <o. to a
sa&e site whenever possi.le+
1?
7"
Hot Work
EGA5-AT:/N F/$M
5ocation%
<ate%
A H EICE55ENT' 2 H "//<' C H FA:$' < H P//$' E H NJA
How were the &ollowing o.<ectives met: A J C ,
5
1+ *pon completion o& this program) participants will .e a.le to:
To understand and learn the elements o& a good hot work program+
7+ ,id the tasks address the purposes o& the activit(P
!+ Please evaluate the speaker: KKKKKKKKKKKKKKKKKK

Trainer 9ame
Lnowledge o& su.<ect
Presentation orderl( and understanda.le
5Fective use o& teaching tools

6small groups) eAplanation) assignments8
%+ What did (ou like the most a.out this activit(P

71
More on bac-'
77
@+ How could this activit( .e improvedP
Additional Comments:
7!

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Preventing Chemical Accidents: Hot Work

7+ ,id the tasks address the purposes o& the activit(P

!+ Please evaluate the speaker: KKKKKKKKKKKKKKKKKK

Presentation orderl( and understanda.le

5Fective use o& teaching tools

%+ What did (ou like the most a.out this activit(P

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