Hot Work Permit Checklist

This checklist is designed to ensure that all necessary safety precautions are taken before, during, and after hot work operations to prevent fires and other hazards [1].

I. Pre-Operation Checks:

A. Permit Authorization:

• Hot work permit is issued and properly authorized by a designated management representative [2].
• Permit indicates the nature of the hazard [3].
• Permit specifies the type and frequency of atmospheric testing required [3].
• Permit outlines safe work procedures and precautionary measures [3].
• Permit identifies required protective equipment [3].
• Permit indicates the date(s) authorized for hot work and identifies the object on which work is to be performed [4].
• The hot work permit is kept on file until completion of the hot work operations [4].

B. Fire Prevention and Protection:

• Hot work area is cleared of combustible materials, or such materials are suitably isolated [3].
• Combustible materials are relocated or covered with fire-resistant materials [1].
• Ensure cutting and welding are scheduled so that plant operations that might expose combustibles to ignition are not started during cutting or welding [2].
• Fire protection and extinguishing equipment are properly located at the site [2].
• Suitable fire extinguishing equipment is immediately available and in a state of readiness [5].
• Confirm fire watch personnel are available at the site, when required [2].
• Additional personnel are assigned to guard against fire during and after the operation, if normal precautions are insufficient [5].
• Personnel are instructed on specific fire hazards and the use of firefighting equipment [5].
• For work on walls, floors, and ceilings, precautions are taken on both sides to prevent fire hazards [5].

C. Atmospheric Testing:

• Atmosphere is tested to ensure it does not contain a flammable substance in a mixture with air exceeding 20% of the substance's lower explosive limit (LEL) for gas or vapors [3].
• Atmosphere does not contain the minimum ignitable concentration for dust [3].
• Suitable tests have been conducted to indicate whether the atmosphere contains a flammable substance in a quantity sufficient to create an explosive atmosphere [6].
• Tests confirm that the work may be safely performed [6].

D. Equipment Inspection:

• Welding and cutting equipment is in good working order [7].
• Hoses are in good condition and properly connected [7].
• Check that the combustion air intake and exhaust discharge are equipped with a flame arresting device or are located outside the hazardous location [3].

E. Personal Protective Equipment (PPE):

• Appropriate PPE, including eye and face protection (welding helmet, safety glasses), gloves, and clothing, is available and in good condition [8].
• Workers are wearing appropriate personal protective equipment when a hot tap is performed on equipment containing hydrocarbons, combustible fluids, superheated steam or any other hazardous material [9].

II. During Operation Checks:

• Monitor the hot work area continuously for any signs of fire or unsafe conditions [6].
• Repeat atmospheric tests at regular intervals appropriate to the hazard [9].
• Ensure continuous safe performance of the hot work by implementing the work procedures [3].

III. Post-Operation Checks:

• Inspect the hot work area for any signs of smoldering or fire after completion of the work [5].
• Maintain fire watch for a sufficient period after the hot work to ensure no possibility of fire exists [1].

IV. Specific Scenarios:

A. Welding or Cutting Containers:

• Used drums, barrels, tanks, or other containers have been thoroughly cleaned to ensure no flammable materials or substances are present [2].
• Pipe lines or connections to the drum or vessel are disconnected or blanked [2].
• All hollow spaces, cavities, or containers are vented to permit the escape of air or gases before preheating, cutting, or welding [2].
• Purging with inert gas is recommended [2].

B. Confined Spaces:

• When arc welding is suspended, electrodes are removed from the holders, and holders are located to prevent accidental contact [2].
• Machine is disconnected from the power source when arc welding is suspended [2].
• Torch valves and gas supply are positively shut off outside the confined area when gas welding or cutting is not in use [2].

V. Management of Change

• Management of change procedures are followed for any changes to process chemicals, technology, equipment, and procedures [10].
• Employees are informed and trained in the change prior to start-up [4].

VI. Emergency Preparedness:

• Emergency action plan is in place and readily accessible [11].
• Emergency contact information is readily available [12].

VII. Approvals:

• Permit Prepared By: _____________________________
• Date: _____________________________
• Permit Approved By: _____________________________
• Date: _____________________________

VIII. Notes/Corrective Actions:

• Document any specific hazards identified and the corresponding corrective actions taken.
• Include any additional safety measures implemented.

IX. References:

• Refer to 29 CFR 1910.252(a) for fire prevention and protection requirements [4].

Disclaimer: This checklist is a tool to assist in identifying potential hazards and is not a substitute for proper training, experience, and judgment. Always refer to applicable safety regulations and company policies.