Module 1: Introduction to Welding and Hot Work Safety

• Definition of hot work (welding, cutting, grinding, brazing, soldering)
• Importance of controlling fire and explosion risks
• Relevant standards: OSHA 29 CFR 1910 Subpart Q, NFPA 51B, ISO 3834

Module 2: Types of Welding and Hot Work Processes

• Arc welding, gas welding, TIG/MIG, cutting, and grinding
• Equipment overview and safe operation basics
• Job-specific hazards for each process

Module 3: Common Hazards in Welding and Hot Work

• Fire and explosion hazards
• Electric shock, burns, UV/IR radiation, and fumes
• Confined space and oxygen deficiency risks

Module 4: Hot Work Permit System

• Purpose and importance of hot work permits
• Step-by-step permit procedure
• Roles and responsibilities of permit issuer and holder

Module 5: Fire Prevention and Control

• Identification of combustible materials
• Safe distances, fire watches, and spark containment
• Fire extinguishers and emergency readiness

Module 6: Ventilation and Fume Control

• Hazards of welding fumes and gases
• Local exhaust ventilation (LEV) systems
• Respiratory protection and air monitoring

Module 7: Electrical and Gas Safety in Welding

• Proper grounding and insulation
• Handling gas cylinders safely (storage, transport, labeling)
• Leak testing and valve operation procedures

Module 8: Personal Protective Equipment (PPE)

• Welding helmets, face shields, gloves, aprons, and boots
• Flame-resistant clothing and hearing protection
• PPE maintenance and inspection

Module 9: Safe Work Practices and Housekeeping

• Pre-job inspection and area preparation
• Safe handling of hot materials and tools
• Preventing trip hazards and clutter in work areas

Module 10: Working in Confined or Elevated Areas

• Special precautions for tanks, vessels, or scaffolds
• Atmospheric testing and ventilation requirements
• Use of standby personnel and rescue readiness

Module 11: Emergency Response and Incident Management

• Immediate actions during fire, burns, or explosion
• First aid for electrical shock and fume inhalation
• Reporting, investigation, and corrective actions

Module 12: Training, Supervision, and Continuous Improvement

• Training requirements for welders and hot work personnel
• Supervisor’s role in permit control and monitoring
• Continuous improvement through audits and lessons learned