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 conducted within the facility, including welding, cutting, grinding, and soldering. It includes the use of all equipment and tools associated with these operations. The scope excludes hot work performed by external contractors, which will be covered under a separate risk assessment.

2. Risk Assessment Methodology

This risk assessment employs a qualitative risk assessment method using a 5x5 risk matrix to determine risk levels. The likelihood of occurrence is rated as Rare, Unlikely, Possible, Likely, or Almost Certain. Severity is rated as Negligible, Minor, Moderate, Major, or Catastrophic. The risk rating is then determined by combining likelihood and severity, resulting in a risk level of Low, Medium, High, or Extreme. Control measures are selected based on the hierarchy of controls (Elimination, Substitution, Engineering, Administrative, and PPE) to reduce risks to acceptable levels. A field-level risk assessment should also be completed prior to starting work. [2]

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	Low	Medium	High	Extreme
Major	Low	Low	Medium	High	High
Moderate	Very Low	Low	High	High	Immediately Dangerous
Minor	Very Low	Very Low	Low	Medium	High
Negligible	Very Low	Very Low	Low	Low	Medium

4. Hazard Identification and Risk Evaluation

1. Fire caused by sparks or hot materials igniting flammable or combustible materials in the work area.

Potential Consequences: Severe burns, property damage, and potential fatalities. [1] [3] [3]

Affected Persons: Workers, 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 bolting or hydraulic shears.
• Use local exhaust ventilation to remove fumes and gases at the source.
• Implement a hot work permit system to ensure proper authorization and control.
• Provide fire-resistant blankets and shields to contain sparks and hot materials.
• Use appropriate PPE, including welding helmets, gloves, and fire-resistant clothing.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Moderate	Medium

2. Exposure to welding fumes and gases, which can cause respiratory irritation and long-term health effects.

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

Affected Persons: Workers and nearby personnel

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Likely	Moderate	High

Control Measures

• Ensure proper ventilation to remove fumes and gases.
• Use respiratory protection, such as respirators, when ventilation is inadequate.
• Monitor air quality to ensure exposure levels are within acceptable limits.
• Provide training on the hazards of welding fumes and gases.
• Implement engineering controls to minimize fume generation.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Minor	Medium

3. Arc flash and exposure to ultraviolet radiation, which can cause eye damage (arc eye) and skin burns.

Potential Consequences: Eye damage, skin burns, and potential vision impairment.

Affected Persons: Workers

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Moderate	Medium

Control Measures

• Use welding helmets with appropriate shade lenses to protect eyes and face.
• Wear appropriate eye protection, such as safety glasses or goggles, when not welding.
• Ensure proper shielding to protect others from arc flash.
• Regularly inspect welding helmets for damage and replace as needed.
• Provide training on the hazards of arc flash and proper eye protection.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Minor	Low

4. Electric shock from faulty equipment or improper grounding.

Potential Consequences: Severe electric shock, burns, and potential cardiac arrest.

Affected Persons: Workers

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Major	Medium

Control Measures

• Ensure equipment is properly grounded to prevent electric shock.
• Use insulated gloves and tools.
• Regularly inspect equipment for damaged cords and connections.
• Avoid working in wet or damp conditions.
• Provide training on electrical safety.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Rare	Minor	Low

5. Musculoskeletal injuries from repetitive motions, awkward postures, or heavy lifting.

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

Affected Persons: Workers

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Moderate	Medium

Control Measures

• Use proper lifting techniques to avoid strain.
• Take frequent breaks to rest and stretch.
• Rotate tasks to reduce repetitive motions.
• Provide ergonomic assessments of workstations.
• Use mechanical aids to assist with heavy lifting.

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 hot work permit should detail the specific work to be done, the hazards involved, and the control measures to be implemented.

• Ensure all hot work equipment is regularly inspected and maintained in good working order.

Regular inspections should include checks for damaged cords, loose connections, and proper grounding.

• Provide appropriate fire-resistant barriers and shields to contain sparks and hot materials.

Barriers should be placed to protect combustible materials and prevent sparks from spreading to other areas.

6. Emergency Preparedness

• Ensure fire extinguishers are readily available and personnel are trained in their use.
• Establish and communicate emergency evacuation procedures, including designated escape routes and assembly points.
• Provide first aid kits and ensure personnel are trained in basic first aid.

7. Training Requirements

• Hot Work Equipment Training: Training on the proper use, maintenance, and inspection of hot work equipment.
• Respiratory Protection Training: Training on the hazards of welding fumes and gases, and the proper use of respiratory protection.
• Fire Safety Training: Training on fire safety, including the use of fire extinguishers and emergency evacuation procedures.

8. Monitoring and Review

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

Monitoring Type	Frequency	Responsible Party	Description
Regular Inspection	Weekly	Safety Officer	Regular inspections of hot work areas to ensure compliance with safety procedures and permit requirements.
Performance Indicator	Monthly	Industrial Hygienist	Air quality monitoring to assess exposure levels to welding fumes and gases.
Audit	Quarterly	Safety Committee	Review of incident reports and near misses related to hot work operations.

9. Special Circumstances

• Hot work performed in confined spaces requires additional precautions, including atmospheric testing and continuous monitoring.
• Hot work performed at height requires fall protection measures, such as safety harnesses and guardrails.
• Weather conditions, such as high winds or rain, may increase the risk of fire or electric shock.

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 when significant changes occur.

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