Hot Work Operations Risk Assessment

Assessment Date: [DATE]

Assessor: [ASSESSOR NAME]

Department/Area: [DEPARTMENT/AREA]

Review Date: [REVIEW DATE]

1. Assessment Scope

This risk assessment covers all hot work operations, including welding, cutting, grinding, soldering, and brazing, performed within the facility. It includes activities conducted by employees, contractors, and temporary workers. The scope encompasses hazard identification, risk analysis, control measure implementation, and emergency preparedness related to hot work. Excluded are hot work activities performed outside of company property or in areas not under direct company control.

2. Risk Assessment Methodology

The risk assessment methodology follows a qualitative approach using a 5x5 risk matrix to determine risk levels based on likelihood and severity. The hierarchy of controls is applied to identify and implement control measures, prioritizing elimination and substitution where feasible, followed by engineering controls, administrative controls, and personal protective equipment.

3. Risk Matrix Reference

The following matrix is used to evaluate risk levels based on likelihood and severity:

		Likelihood
Rare	Unlikely	Possible	Likely	Almost Certain
Severity	Catastrophic	Low	Medium	High	Extreme	Extreme
Major	Low	Medium	High	High	Extreme
Moderate	Low	Low	Medium	High	High
Minor	Low	Low	Low	Medium	High
Negligible	Low	Low	Low	Low	Medium

4. Hazard Identification and Risk Evaluation

1. Fire and explosion due to ignition of flammable or combustible materials by sparks, heat, or open flames from hot work activities.

Potential Consequences: Severe burns, property damage, equipment damage, and potential fatalities.

Affected Persons: Workers, contractors, visitors, and nearby personnel

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Major	High

Control Measures

• Eliminate the need for hot work by using alternative methods such as mechanical fastening or cold cutting techniques.
• Use welding blankets or fire-resistant barriers to contain sparks and slag.
• Ensure proper ventilation to remove fumes and gases.
• Implement a hot work permit system to authorize and control hot work activities.
• Provide appropriate PPE, including fire-resistant clothing, gloves, and eye protection.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Moderate	Medium

2. Exposure to hazardous fumes and gases, such as metal fumes, ozone, and nitrogen oxides, during welding and cutting operations.

Potential Consequences: Respiratory irritation, metal fume fever, long-term respiratory illnesses, and potential carcinogenic effects.

Affected Persons: Workers, contractors, and nearby personnel

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Likely	Moderate	High

Control Measures

• Ensure proper ventilation to remove welding fumes and gases.
• Use local exhaust ventilation (LEV) systems to capture fumes at the source.
• Provide respirators for workers when adequate ventilation is not available.
• Implement a respiratory protection program, including fit testing and training.
• Monitor air quality to ensure exposure levels are within permissible limits.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Minor	Medium

3. Electric shock due to contact with live electrical parts of welding equipment or faulty wiring.

Potential Consequences: Electrical burns, cardiac arrest, and potential fatalities.

Affected Persons: Workers and nearby personnel

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Major	Medium

Control Measures

• Use welding screens or barriers to protect others from arc flash and sparks.
• Ensure proper grounding of welding equipment to prevent electric shock.
• Inspect welding cables and equipment regularly for damage.
• Provide insulated gloves and clothing to protect against electric shock.
• Train workers on electrical safety and lockout/tagout procedures.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Minor	Low

4. Arc flash and UV radiation exposure causing eye damage (arc eye) and skin burns.

Potential Consequences: Temporary or permanent vision impairment, skin burns, and increased risk of skin cancer.

Affected Persons: Workers and nearby personnel

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Likely	Moderate	High

Control Measures

• Provide appropriate eye protection, such as welding helmets with the correct shade lens.
• Use welding screens or barriers to protect others from arc flash.
• Ensure proper ventilation to reduce exposure to UV radiation.
• Educate workers on the risks of arc flash and the importance of eye protection.
• Regularly inspect welding helmets for damage.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Minor	Medium

5. Musculoskeletal injuries due to awkward postures, repetitive motions, and heavy lifting during hot work activities.

Potential Consequences: Strains, sprains, back injuries, and other musculoskeletal disorders.

Affected Persons: Workers

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Moderate	Medium

Control Measures

• Ensure proper housekeeping to prevent slip, trip, and fall hazards.
• Use anti-fatigue mats to reduce strain from prolonged standing.
• Provide ergonomic tools and equipment to minimize physical strain.
• Implement a stretching and exercise program to prevent musculoskeletal disorders.
• Train workers on proper lifting techniques and ergonomic principles.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Minor	Low

5. General Control Measures

• Implement a hot work permit system to authorize and control hot work activities.

The permit should specify the location, time, and duration of the hot work, as well as the required safety precautions and equipment.

• Ensure proper housekeeping to prevent the accumulation of flammable and combustible materials in hot work areas.

Regularly clean and inspect hot work areas to remove any potential fire hazards.

• Provide and ensure the use of appropriate personal protective equipment (PPE), including fire-resistant clothing, gloves, and eye protection.

PPE should be inspected regularly for damage and replaced as needed.

• Ensure proper ventilation to remove fumes and gases generated during hot work activities.

Use local exhaust ventilation (LEV) systems to capture fumes at the source.

• Conduct regular safety inspections of hot work areas and equipment to identify and correct hazards.

Inspections should be documented and include corrective actions taken.

6. Emergency Preparedness

• Ensure fire extinguishers are readily available and appropriate for the types of fires that could occur.
• Establish and communicate emergency evacuation procedures.
• Provide training on fire safety and emergency response.
• Conduct regular fire drills to practice emergency procedures.
• Establish a fire watch for a minimum of 30 minutes after hot work is completed to monitor for any signs of fire.

7. Training Requirements

• Hot Work Equipment Safety: Workers must be trained on the safe use of hot work equipment, including welding machines, cutting torches, and grinding equipment.
• Hot Work Hazard Awareness: Workers must be trained on the hazards associated with hot work, including fire, explosion, electric shock, and exposure to hazardous fumes and gases.
• Personal Protective Equipment (PPE): Workers must be trained on the proper use of personal protective equipment (PPE) for hot work, including fire-resistant clothing, gloves, and eye protection.
• Emergency Procedures: Workers must be trained on emergency procedures, including fire response and evacuation.
• Hot Work Permit System: Workers must be trained on the requirements of the hot work permit system.

8. Monitoring and Review

Review Frequency: Annually, and after any incident or significant change in hot work procedures or equipment

Monitoring Type	Frequency	Responsible Party	Description
Regular Inspection	Weekly	Safety Department	Regular inspections of hot work areas to ensure compliance with safety procedures and the hot work permit.
Performance Indicator	Monthly	Occupational Health Nurse	Air quality monitoring to ensure exposure levels to fumes and gases are within permissible limits.
Audit	Quarterly	Safety Committee	Review of incident reports related to hot work to identify trends and areas for improvement.
Regular Inspection	Monthly	Maintenance Department	Ensure that all hot work equipment is inspected regularly and maintained in good working order.
Audit	Annually	Safety Manager	Periodic review of the hot work program to ensure its effectiveness and relevance.

9. Special Circumstances

• Hot work performed in confined spaces requires additional precautions, including atmospheric testing, ventilation, and rescue planning.
• Hot work performed at heights requires fall protection measures, such as guardrails or fall arrest systems.
• Hot work performed in wet or damp conditions requires additional electrical safety precautions.
• Hot work performed near flammable liquids or gases requires special precautions, such as purging and inerting.
• Lone work should be avoided; ensure a buddy system is in place or implement regular check-ins.

Approval and Sign-off

This risk assessment has been reviewed and approved by:

Assessor: _________________________ Date: __________

Manager/Supervisor: _________________________ Date: __________

Safety Representative: _________________________ Date: __________

This risk assessment must be reviewed annually, and after any incident or significant change in hot work procedures or equipment or when significant changes occur.

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