Fire Safety: Managing Risks for Industrial Hot Work

A Job Hazard Analysis is the most critical part of the job—this gives us an opportunity to go in
the field with operations and review, recognize, and control hazards at the job site or in the area.

 By Jeremiah Q. Varner
 Apr 01, 2018

Once a fire ignites, it can spread rapidly and out of control in seconds, especially in industrial
refineries and petrochemical facilities where highly flammable chemicals are manufactured and
stored. Flammable and combustible liquids are classified in the NFPA 30 Code published by the
National Fire Protection Association (NFPA) based on their flash point and additional criteria
that affect any potential fire risks. Fire safety requires managing the risks or mitigating the
causes of potential fires and explosions. Hot work is one of the leading causes for fires in
industrial facilities across the nation, according to NFPA.

Hot Work
Hot work is any open-flame welding, torching, brazing, and cutting or the use of any spark-
producing power tools, such as a grinder. These activities and tools are common ignition sources.
Other ignition sources could be a static discharge from a cell phone or possibly a vehicle in the
area that has flammable gases present. What does hot work mean to you and me in a large-scale
industrial chemical facility? It could mean a wide array of things, and there are many scenarios,
such as retrofitting some new piping in the plant, that require welding and grinding for hours
upon hours while the plant is in operation.

Managing Our Risk

During this process, one of the very first questions we should ask ourselves is can we eliminate
performing hot work completely? What are our options to reduce and/or eliminate our risk? Can
the task be completed without producing an open flame? Sometimes you won’t be able to
eliminate the hazard, but you can review alternatives such as the type of tools available. Is there
another tool that could be substituted for the hot work project to reduce the hazard? Using a band
saw to cut a piece of pipe instead of using a grinder or open-flame torch may take longer, but the
hazard and chances of injury to the worker are reduced. We should review our engineering and
administrative controls in place—for example, isolating other people in the area from sparks with
the use of fire retardant blankets; keeping people out of the area with the proper barricading and
tags if there is overhead hot work; and checking for combustible materials, flammable liquids,
flammable gases, flammable metals, flammable dust particulates, and electrical equipment.

A lot of these items should be covered during the Job Hazard Analysis, Permitting, and Hazard
Field Checks with maintenance and operations, and we will touch on that more below. The
training is paramount for everything to come together, and lot of thorough training should take
place, such as proper documentation of hot work permitting, Job Hazard Analysis, Hazard Field
Checks, as well as fire watch roles, responsibilities, and expectations. Not only should training
take place, the training should be continuous in order to stay proficient in whichever role you
play in the job. It is important that the proper tools have been given to the craftsmen to manage
the risk they have been dealt, such as proper PPE to ensure all members involved are protected.
As an industry, it is essential that we are striving for an all-in engaging and sustainable safety
culture at all levels.

Hot Work Program and Permitting

It is important to have a good, comprehensive hot work program and permitting process. This
gives the maintenance and operations group a chance to engage and talk about the area where the
work is going to be performed, as well as the equipment being worked on. It is critical in our
industry that all flammables, combustibles, and any other ignitable material are moved 20 to 35
feet away, covered with proper fire retardant blankets for containment, and stored properly as
required by OSHA.

Discussions should include lockout /tagout (LOTO) and whether the equipment is ready for
maintenance—if there is poor communication, things can go downhill in a hurry. During the
field hazard review, it is important that the two groups work together on identifying the hazards
and controlling them. Also, if there is a potential for ignitable gases in the area, some companies
may require testing in the area with a gas meter to check for any atmospheric ignitable sources,
to ensure the area is suitable to perform hot work tasks.

Once we have a fire watch in place with all of the proper tools required, then we are good to
commence work. Once the work area is cleaned up and hot work is complete, the fire watch
should stay in the area for at least 30 minutes to scan for any hot spots or rekindling of potential
fires.

It Takes a Team Partnership

In order to create a zero incident hot work project, it takes a team from start to finish. It takes
several different members—maintenance; operations; on-site contractors; engineering;
environmental, health and safety department; and any other parties needed to ensure we take the
proper steps to have a successful hot work operation.

 It starts with the proper planning: maintenance planners, operations, and engineering
communicating about what needs to be cut and replaced, for example.
 Some companies may require the use of a Positive Line Identification policy to
supplement as a communication tool. The Positive Line Identification policy should be
detailed on where a cut may exactly need to be and have the proper people involved in
the process.
 Contractors or company personnel needed and verifying it is the right contractor or
person for the job.
 It is up to the maintenance and operations teams to have a clear line of communication to
make certain they are working on the right piece of equipment, where the cut is being
made, for example; the equipment is depressurized or de-energized, locked out/tagged
out; and all other procedural steps have taken place before hot work begins.
 A Job Hazard Analysis is the most critical part of the job—this gives us an opportunity to
go in the field with operations and review, recognize, and control hazards at the job site
or in the area. Operations should review anything safety-related in the area, such as wind
direction, location of the nearest evacuation shelter, safety eyewash/showers and fire
extinguishers, and ensuring all combustibles are out of the area.
 The fire watch has the most significant role during hot work activities; he or she is
accountable for ensuring no fires take place. The fire watch should have a fire
extinguisher that is the correct type and large enough to mitigate an incipient stage fire.
 There is the potential for hazards to change in a matter of seconds, and anything can
happen, so everyone must stay vigilant and keep their head on a swivel at all times. If we
take the proper steps on recognizing our hazards in the beginning, then we are already
heading in the right direction. Going through these processes may take longer than the
hot work job itself, but our goal should be zero incidents. By taking the proper time to
identify, plan, and manage our risks prior to performing hot work, we can reach that goal
together.

 There Is Always Room for Improvement
In an article from the U.S. Chemical Safety and Hazard Investigation Board (CSB), they
investigated incidents involving deaths during hot work in and around industrial storage
tanks. There were a lot of improvement opportunities and hazards that could have been
mitigated, but we want this to be about the lessons learned and how we can improve
going forward in our industry. Here are seven key lessons from recent hot work accidents
from the CSB:
 1. Use alternatives—Whenever possible, avoid hot work and consider alternative
methods.
 2. Analyze the hazards—Prior to the initiation of hot work, perform a hazard assessment
that identifies the scope of the work, potential hazards, and methods of hazard control.
 3. Monitor the atmosphere—Conduct effective gas monitoring in the work area using a
properly calibrated combustible gas detector prior to and during hot work activities, even
in areas where a flammable atmosphere is not anticipated.
 4. Test the area—In work areas where flammable liquids and gases are stored or handled,
drain and/or purge all equipment and piping before hot work is conducted. When welding
on or in the vicinity of storage tanks and other containers, properly test and if necessary
continuously monitor all surrounding tanks or adjacent spaces (not just the tank or
container being worked on) for the presence of flammables, and eliminate potential
sources of flammables.
 5. Use written permits—Ensure that qualified personnel familiar with the specific site
hazards review and authorize all hot work and issue permits specifically identifying the
work to be conducted and the required precautions.
 6. Train thoroughly—Train personnel on hot work policies/procedures, proper use and
calibration of combustible gas detectors, safety equipment, and job-specific hazards and
controls in a language understood by the workforce.
 7. Supervise contractors—Provide safety supervision for outside contractors conducting
hot work. Inform contractors about site-specific hazards, including the presence of
flammable materials.

 (U.S. Chemical Safety and Hazard Investigation Board, Feb. 2010, No. 2009-01-SB).
 Final Thoughts
When it comes to industrial fire safety and hot work in our industry, it is important to
start the process of engaging with positive interactions and making good decisions
together. Before any hot work begins, any consideration of potential hazards and control
measures should take place, and we should be asking ourselves, how are we going to
safely and efficiently manage our risks?