Hot Work HIRA (Hazard Identification and Risk Assessment)
Hot work refers to operations involving open flames or producing heat and sparks, such as welding, cutting, grinding, brazing, soldering, or torch application. These activities pose a high risk of fire, explosion, and burns, especially in environments containing flammable materials or gases.
A structured HIRA for hot work activities is critical to identifying associated hazards, assessing risks, and implementing control measures that ensure a safe working environment.
Objective of Hot Work HIRA
- To systematically identify hazards involved in hot work.
- To assess the risk severity and likelihood using a structured matrix.
- To propose effective engineering, administrative, and PPE-based controls.
- To enhance awareness and preparedness among hot work personnel.
Scope
This HIRA covers hot work activities in all types of workplaces, including:
- Welding (arc, MIG, TIG, gas welding)
- Gas cutting and flame cutting
- Grinding and metal polishing
- Torch soldering or brazing
- Surface heating or heat shrinking
- Hot tapping and spark-producing work
Step-by-Step HIRA for Hot Work
1. Activity Description
Performing operations that generate flame, spark, or heat capable of igniting flammable materials or causing burns. Typically carried out in fabrication, repair, and maintenance work.
2. Hazard Identification Table
| S. No. | Hazard | Potential Effects | Persons at Risk |
|---|---|---|---|
| 1 | Fire due to sparks or flame | Burns, property damage, fatality | Workers, nearby personnel |
| 2 | Explosion due to flammable gas or vapors | Fatal injuries, structural collapse | Welders, gas cutters, all personnel |
| 3 | Inhalation of welding fumes | Respiratory problems, long-term health effects | Hot work operators |
| 4 | Eye injury from arc flash or sparks | Temporary or permanent blindness | Welders, bystanders |
| 5 | Burns from hot surfaces or slag | Skin burns, scarring | Operators |
| 6 | Contact with pressurized gas cylinders | Blast injury, flying debris | Gas cutter, welder |
| 7 | Electrocution from faulty welding machines | Electric shock, burns, death | Welders, electricians |
| 8 | Tripping on cables and hoses | Injuries due to fall | Operators, helpers |
| 9 | Fire in confined spaces | Smoke inhalation, asphyxiation | Confined space workers |
| 10 | Flashback in gas lines | Explosion or fire | Oxy-acetylene torch users |
3. Risk Assessment Matrix
Risk Rating = Likelihood (L) × Severity (S)
| Hazard | L | S | Risk Rating | Risk Level |
|---|---|---|---|---|
| Fire from sparks | 4 | 5 | 20 | Critical |
| Explosion due to flammable vapor | 3 | 5 | 15 | High |
| Inhalation of fumes | 4 | 3 | 12 | High |
| Arc flash eye injury | 4 | 4 | 16 | Critical |
| Burns from slag/surfaces | 3 | 3 | 9 | Medium |
| Gas cylinder mishandling | 2 | 5 | 10 | High |
| Electrical hazards | 3 | 5 | 15 | High |
| Tripping hazard | 4 | 2 | 8 | Medium |
| Fire in confined space | 3 | 5 | 15 | High |
| Flashback | 2 | 5 | 10 | High |
4. Control Measures
Engineering Controls:
- Use of fire-resistant blankets and spark arrestors.
- Installation of local exhaust ventilation (LEV) for fume extraction.
- Spark-proof tools and explosion-proof lighting in hazardous zones.
- Welding screens to protect nearby workers.
- Flashback arrestors installed on cutting torches.
Administrative Controls:
- Issue of Hot Work Permit (valid for a specific duration and task).
- Conduct gas tests in enclosed/confined areas.
- Assign a fire watch with an extinguisher nearby during and after hot work.
- Remove or shield all combustible materials within a 15-meter radius.
- Display “Hot Work In Progress” signage at the work area.
- Only trained and certified welders and cutters allowed.
Personal Protective Equipment (PPE):
- Flame-resistant welding jacket or apron.
- Welding helmet with proper shade for eye protection.
- Welding gloves (leather or Kevlar).
- Safety shoes with heat-resistant soles.
- Respiratory protection when working in poor ventilation.
5. Safe Work Procedure (SWP)
Pre-Hot Work:
- Identify hazards and complete a Hot Work Permit.
- Ensure gas cylinders are in upright, secured position.
- Remove flammable items and cover surfaces with fire blankets.
- Perform gas detection and ventilation in confined spaces.
- Inspect welding cables, torch valves, regulators, and PPE.
During Hot Work:
- Use only flame-proof PPE and face protection.
- Do not leave the flame unattended.
- Maintain a safe distance between gas cylinders and the flame (min. 6 meters).
- Ensure someone is assigned as a fire watch.
- Keep portable fire extinguisher and first aid nearby.
Post Hot Work:
- Inspect the area for embers, smoke, or heat after job completion.
- Sign off the Hot Work Permit after cooling is confirmed.
- Store gas cylinders and tools properly.
- Report any fire incidents or equipment damage.
6. Emergency Preparedness
- Fire extinguishers (ABC or CO₂ type) must be located near hot work zones.
- Emergency eye wash and shower station in case of burn/fume exposure.
- Fire watch to continue for at least 30–60 minutes post-work.
- Conduct fire drills and emergency response training regularly.
- Maintain updated emergency contact list on site.
7. Roles and Responsibilities
| Role | Responsibility |
|---|---|
| Permit Issuer (HSE/Engineer) | Authorize hot work, verify controls, inspect site |
| Fire Watch | Monitor for fire and raise alarm in case of incident |
| Welder/Operator | Follow safe practices, wear PPE, check equipment |
| Supervisor | Ensure only authorized persons perform hot work |
| Gas Cylinder Handler | Store, transport, and secure cylinders safely |
| First Aider | Provide assistance in case of burns or fume exposure |
Summary of Key Recommendations
- Always issue and follow the Hot Work Permit System.
- Remove flammable materials from the area or cover with fire blankets.
- Maintain a dedicated fire watch during and after work.
- Use flashback arrestors and check gas hoses before use.
- Ensure exhaust ventilation in confined or enclosed areas.
- Use only certified PPE suitable for hot work.
- Store gas cylinders upright and at a safe distance from hot zones.
- Never perform hot work near volatile materials or unknown residues.
Monitoring and Review
- Weekly safety inspections of welding and gas-cutting operations.
- Periodic maintenance of welding machines and gas hoses.
- Regular review of near-misses and fire incidents.
- Audit of hot work permit records and compliance.
- Refresher training for hot work safety and fire response.
Conclusion
Hot work activities are inherently dangerous but necessary in many industrial settings. Without proper hazard identification and control, they can lead to catastrophic fires, explosions, or serious injuries. A detailed HIRA ensures these risks are evaluated and managed effectively.
Through engineering safeguards, strict administrative protocols, and appropriate PPE, organizations can ensure hot work is performed safely and efficiently, protecting both workers and property.
Excavation Work HIRA (Hazard Identification and Risk Assessment)
What is a Job Safety Analysis (JSA)? Format, Benefits & Examples
Understanding the Hierarchy of Controls in Workplace Safety
Types of Hazards in the Workplace: Physical, Chemical, Biological, Ergonomic, and More
What is Risk Assessment? Step-by-Step Guide with Real Examples
