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Preventing Chemical Accidents: Hot Work

Preventing Chemical Accidents

Hot Work

First Edition

Process Safety Management Trainingfrom the

NJ Work Environment Concil

This material was produced under grant SH-171!-"-#"-$-!% &rom the 'ccupational Sa&et( and HealthAdministration) *+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 organiationsimpl( endorsement .( the *+S+ 2overnment+ This curriculum is revised &rom materials originall(developed .( the *nited Steelworker3s Ton( 4aocchi Center &or Sa&et() Health) and 5nvironmental5ducation and produced .( the Steelworkers Charita.le and 5ducational 'rganiation) &unded in whole

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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

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A!ot WEC

The 9ew erse( Work 5nvironment Council 6W5C8 is a non-pro;t

colla.oration o& organiations working &or sa&e) secure

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Preventing Chemical Accidents

-ne.#ected releases o& highl( haardous toic) reactive) or0amma.le chemicals create the possi.ilit( o& a disaster &or

workers) emplo(ers) and communities+

/SHA0s Process Safety Management Standard helps preventaccidental releases o& highl( haardous chemicals) thus protectingemplo(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 approximately1"" &acilities)including certain chemical plants) oil re;neries) &ood processors)electric utilities) warehouses) and pu.lic and private sector waterand sewage treatment operations+ PS4 ma( also cover othert(pes o& &acilities+ PS4 has special provisions &or contractorsworking in covered &acilities+

WEC0s training crriclm covers ke( aspects o& the PS4standard+ Training introduces the concept o& s(stems o& sa&et(and accident prevention and wh( &acilities should esta.lish an

organiational structure to oversee PS4 implementation+ W5Caddresses 'SHA3s per&ormance-.ased reBuirements &or a plantmechanical integrit(D program+ Training also covers accident)incident) and near-miss investigations) &ocusing on root causes+W5C also can provide training on related su.

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$a: 6#"?8 #?@-%""5-4ail: dpatelGn

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The Small "ro# Activity Method

2asic StrctreThe Small 2roup Activit( 4ethod 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# TasksI $e#ort(2ackI 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 groupsuse their eperience and the &actsheets to solve pro.lems andmake

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around economic and health and sa/ety issues /or .or-ers and /urther developed theprocedure into SGAM' The 0e. 1ersey ,or- nvironment Council has used SGAM since#$23'

Three 2asic 5earning E.changesThe Small 2roup Activit( 4ethod 6S2A48 is .ased on the idea thatever( 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 sharein&ormation+ /t is .ased on three learning echanges:

6 Worker(to(Worker6 Worker(to(Trainer6 Trainer(to(Worker

Worker(to(Worker%4ost o& us learn .est &rom each other+ S2A4is set up in such a wa( as to make the worker-to-worker echangea ke( element o& the training+ The worker-to-worker echangeallows participants to learn &rom each other .( solving pro.lemsin their small groups+

Worker(to(Trainer%ecture-st(le training assumes that thetrainer knows all the answers+ With S2A4 it is understood that the

trainers also have a lot to learn and this is the purpose o& theworker-to-trainer echange+ /t occurs during the report-.ack and itis designed to give the trainer an opportunit( to learn &rom theparticipants+

Trainer(to(Worker%This is the trainer3s opportunit( to clear upan( con&usion and make points the( think are ke(+ J( waiting untilthe summar( section) trainers know .etter what people need toknow+

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The Factsheet $eading Method

The process descri.ed .elow &ocuses ever(one on the importantin&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.ers6&actsheets8 are distri.uted+ The assigned num.ers correspond to$actsheets 1 through on the &ollowing pages+

/nce everyone has read their assigned factsheetsindividally' yor scri!e +ill go arond the ta!le and askeach of yo to e.#lain to the gro# +hat yo havelearned, Factsheets shold !e e.#lained in the orderassigned 7& throgh 89' since the factsheets !ild on the

#revios one, :n this +ay' +e all start at the same #laceand +ith the same information,

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Activity ;% Hot Work

Pr#ose

To understand and learn the elements o& a good hot workprogram+

This Activit( has one task+

1

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Scenario%

Art and >a( were sent to the Tank $arm to replace .earings on aisopropanol pump located on the alcohol pad+ The( &ound the

.earings &roenD in place+ When Art told his supervisor the(would have to pull the pump) he said) et3s see i& we can3t pullthose .earings in placeM we3ve got too much downtime in thatarea alread(+D $irst the( tried to loosen the .earings with a.earing heater) a power&ul electric heat gun) without success+>a( then called a welder who heated the casing with her torchuntil the .earings came &ree+ While the welder was there) thesupervisor had her weld .rackets on an /-.eam so he could installa Warning-$lamma.le AreaD sign+

A piece o& slag &rom the welding rolled into a near.( pile o& dampwooden shims+ A&ter the mechanics and the welder le&t the area)the wood .egan to smolder and then .urst into 0ames+ At thesame time an operator .egan to charge ethanol to his unit .(remote computer control+ The ethanol trans&er pump started toleak around its mechanical seal creating a pool o& alcohol on thepad+ The vapors &rom the pool traveled towards the ;re) whichthen ignited them+

The ;re spread instantl( to the pump and grew in intensit( as theheat increased the sie o& the leak+ The tank &arm operator sawthe ;re) sounded the alarm and attacked the ;re with anetinguisher+ She was overcome .( vapors and &ell unconscious+Nuick response .( the in-plant emergenc( response team savedher li&e and stopped a potentiall( disastrous ;re+

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Task%

:n yor gro#s' choose a scri!e, estions,

&, What cold have !een done to #revent this ?re@ 5istthe 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 !emade to im#rove the #rogram@ Please list and e.#lain,

!

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Factsheet &

What :s Hot Work and Why :s :t HaBardos@

'SHA de;nes hot work as: work involving electric or gaswelding) cutting) .raing or similar 0ame or spark-producingoperations+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 .epresent+

When we cut) weld or grind in our &acilities) literall(

thousands o& ignition sources in the &orm o& sparks and hotslag 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 ;reEeplosion haards insometimes distant areas+

%

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Source: 9$PA @1J $ire Prevention in *se o& Cutting and Welding Processes)D 1??+

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Factsheet 3

Hot Work May 2e More Than o E.#ect

An(thing com.usti.le or 0amma.le can .e ignited .( hot work+

Welding) cutting and .raing are prett( o.viousM .ut what a.outthose other 0ame or spark-producing operationsD that 'SHAtalks a.out

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) itis 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 haards o& the process 6solvent vapors) 0amma.legases and eplosive dust-in-air mitures) etc+8+ Jut waitM it3s eas(to overlook other com.usti.le materials in a hot work area likegrass) de.ris) trash) pallets and ;.er drums+ /t pa(s to check thearea out thoroughl(+

Move itD

4ove com.usti.le materials at least !@ &eet &rom the hot workarea+ /& the( can3t .e moved) the( must at least .e protectedwith 0ame-proo&ed covers or shielded with guards or curtains+5dges o& covers at the 0oor should .e tight to prevent sparks &romgoing under them+ Com.usti.le 0ooring should .e wet down or

#

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protected .( ;re-resistant shields+ Cover 0oor drains) trenches)sewer .oes) etc+

Source: 'SHA 1?1"+@6a8M and 9$PA @1J $ire Prevention in *se o& Cutting and Welding

Processes)D 1??+Factsheet 4

Hot Work% or 5ast $esort

/n man( chemical plants and re;neries) it has .ecome routine todo 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 andturnarounds &or maintenance are held much less &reBuentl( than

in the past+ 5ven when such work is scheduled) the length o& timeallowed is enough to take care o& onl( the most serious workorders+

2t remem!er' it is almost al+ays safer to move that #ieceof e>i#ment ot of the #rocess area to a safe #lace!efore doing hot +ork on it,

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Source: Jased on interviews with &ormer 'CAW 69ow *SW8 mem.ers in the video) 'ut o&Control)D produced .( the 'rganiing 4edia Pro

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Factsheet =

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 orwelding are o&ten spread over a large area+ This makes itimpossi.le &or grinders) welders or torch operators to do theirwork and watch &or ;res too+ 'SHA sa(s a ;re watch must .eassigned to the

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Factsheet

What0s a Fire Watch@

A ?re +atch is someone +ho , , , +ell , , , +atchesD

He or she continuousl( monitors the hot work area &or ;res thatma( .e caused .( 0(ing sparks and an( changes in thesurrounding conditions that ma( make the hot work unsa&e+ Theke( word here is continuousl(+ This is not a

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'SHA 1?1"+@ 6a8 6///8 6%8 68+

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Factsheet ;

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 .econsidered .e&ore issuing a permit:

E.#losive atmos#heresHot work o.viousl( can3t .e done near eplosive atmospheres+

The area should .e checked with a com.usti.le gas anal(er atdiFerent levels+ 5ven i& the air is clear) will it sta( that wa(Continuous monitoring should .e standard practice+

Near!y com!sti!les4ove com.usti.le materials in the area !@ &eet &rom the hot workarea+ /& impractical) protect them with 0ame-proo& covers orguards+

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 ahaardous condition) those operations must .e made sa&e untilthe hot work is ;nished+ /& there are 0oor openings) gratings) wallopenings or open ductwork or conve(ors that could allow sparks&rom the hot work to .e carried into another area) the( must .ecovered or .locked+

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Factsheet ; continued

Noti?cation of all #ersons involved'perators on near.( units) supervisors) maintenance or otherworkers near.( and contractors must .e aware o& the hot workgoing on and o& the related haards+ Posting a notice or sign isrecommended also+

Esta!lishment of a ?re +atch/n addition) a hot work permit must include the date and time thework is authoried and must identi&( the eBuipment to .e workedon+ The permit must .e kept on ;le until the hot work operation iscompleted+

>emem.er) i& the nature o& the

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Sources: 'SHA 1?1"+11?M and 9$PA @1J $ire Prevention in *se o& Cutting and WeldingProcesses)D 1??+

1%

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Factsheet

Com!sti!le "as AnalyBers

How do (ou tell i& an area is clear o& 0amma.le gases or vapors

4ost plants use com.usti.le gas anal(ers+ These are usuall(small) hand-held units that test the air and give a readingepressed in percent lower eplosion limit 658+ '&ten anal(ers&or o(gen and other contaminants are com.ined in the sameunit+

Percent 5o+er E.#losion 5imit 75E59$lamma.le gas will ignite onl( when the miture o& gas and air isin the right ratio+ Too little gas and the miture is too lean to

.urn) too much gas and the miture is too rich+

What concentration is safe@Sa&et( concentrations are not speci;ed under 'SHA3s ProcessSa&et( 4anagement standard+ Jut 'SHA3s Con;ned SpaceStandard speci;es a maimum percent 5 o& 1" percent &or workinside a con;ned space+ However) some plants will not do hotwork i& an( positive reading at all shows up on an anal(er+'thers use readings o& one percent or three percent o& the 5 astheir cut-oF point+

Ho+ often is enogh@4ost plants onl( sample when the permit is issued+ A &ew repeatthe monitoring at regular time periods+ The .est protection isoFered .( continuous monitoring+ This can .e done .( areamonitors with noticea.le alarms or .( eBuipping ;re watches6a&ter proper training8 with anal(ers during the hot work+

1@

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Sources: 'SHA 1?1"+1%#M and 9ational Sa&et( Council)Accident Prevention Manual /or4usiness and ndustry) 1"th 5dition) /tasca) /: The 9ational Sa&et( Council) 1??+

1#

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Factsheet 8

Monitoring the Monitors

4onitoring results are onl( as good as the eBuipment .eing used

and the training and eperience o& those using it+ So .e sure that:

'nl( eperienced) trained workers use a com.usti.le gas

monitor+

*nits have &ull( charged .atteries+

The anal(er is intrinsicall( sa&e 6eplosion 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 isver( high in concentration+ /& the o(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 aFectreadings+

4onitors do not give instantaneous readings+ The( reBuire

as longas !" seconds to per&orm the anal(sis+ /& an auiliar( pumpand tu.ing are used to sample a con;ned space or otherarea) allow at least two more seconds per &oot o& sample

tu.ing &or the sample to reach the monitor+

/& the results o& an( anal(er are suspect in an( wa() retest

with another unit immediatel(+

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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"th5dition) /tasca) /: The 9ational Sa&et( Council) 1??+

Smmary% Hot Work

1+ Hot work is an(

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#+ Hot work areas should alwa(s .e monitored &or 0amma.legases .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

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Preventing Chemical AccidentsHot Work

EGA5-AT:/N F/$M

5ocation%

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More on bac-'

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@+ How could this activit( .e improved

Additional Comments:

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