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Safety Practices for Welding on Oil Tanks

The term "hot work" is defined by OSHA as "any spark-producing operation, including welding, brazing, grinding, burning . . ." Indeed, the U.S. Chemical Safety and Hazard Investigation Board (CSB) states that most accidents resulting from welding on oil tanks occur when easily ignited flammable vapors come into contact with a spark or flame. Fatal accidents can be prevented by educating employees about testing and monitoring for flammable vapors during welding operations.

  1. Using Alternate Methods

    • If at all possible, do not engage in hot work near areas that handle, process, or store flammable gases or liquids. Find alternate methods of operation that do not present a fire hazard.

    Potential Hazards List

    • Before hot work has begun, the work site must be assessed for potential hazards. A site foreman or manager must walk the site taking note of what could become or already is a hazard, such as leaking pipes and sources of petroleum that cannot be removed. The potential hazards list is used to determine what methods or safety procedures need to be in place to prevent workplace injury or fatal accidents.

    Safety Procedures

    • Petroleum can form a highly flammable gas and must be removed from the site to eliminate a source of combustible gas vapor. Anything containing petroleum, such as equipment, tanks and piping, must be drained and purged of its contents before hot work can begin. Storage areas and facilities where flammable gases and liquids are handled as well as storage tanks and containers near the work site should be tested with an LEL3 meter.

    Combustible Gas Monitoring

    • The LEL3 meter (combustible gas detector) is used to measure flammable gas. Testing for gas vapor must be done before and during hot work. If the LEL3 (combustible gas vapor) level rises to 10 percent, work must be stopped immediately. A reading of 10 percent or higher indicates high concentration of flammable gas vapor in the area. Once work has stopped, the person responsible for monitoring and testing the work site will seek the flammable vapor source and attempt to eliminate it. Sometimes flammable gas leaks from loose valves or pipes that can be tightened or resealed to stop gas from escaping.

    Using Written Permits

    • The CSB requires participating personnel to sign written permits. The mandatory permits should include information about what the job entails so employees know the risks before beginning. The permit should clearly state safety requirements and precautionary measures that need to be taken to keep the workplace safe. Employees that do not sign the permits should not be allowed on the work site; they could unwittingly do something to harm themselves or others.

    Thorough Training

    • Employees doing hot work on oil tanks should attend regular safety meetings to review safety procedures, proper use of combustible gas detectors and how to calibrate them for accurate readings and correct use of safety equipment and how to spot safety hazards to prevent accidents and injuries.

    Outside Contractor Supervision

    • Outside contractors hired to do hot work for a welding company, although not regular employees, still need to be kept safe. Appointing a qualified supervisor to watch over their work can ensure that they are following proper safety protocols and work methods.

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