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Hot Work in Pipe Rack | Safety Dos and Don’ts

Hot Work in Pipe Rack | Safety Dos and Don’ts | Toolbox Talk
Hot Work in Pipe Rack |- Safety Dos and Don’ts

Hot Work in Pipe Rack | Safety Dos and Don’ts

Hot Work in Pipe Rack Safety Precautions: Pipe rack in oil and gas installations is the most vulnerable area where oil handling pumps are also installed underneath. With most pumps and pipeline handling hot products above flash points, in the event of leak, there is a risk of fire and explosion.
Also, in the jet fire event (due to pressurized hydrocarbon in the pipeline) and pool fire, there is a potential risk of the Pipe rack collapsing due to structural failure. To prevent this, pipe rack supports are provided with fire proofing.
When performing any hot work in oil handling pipelines, special care must be taken to avoid an explosion which could result in fatality and/or loss of property.
Dos and Don'ts of Hot Work in Oil Pipelines can be used to educate workers to ensure safety precautions during performing hot work in pipe rack area. All these safety dos and don’ts must be a part of work permit and job safety analysis.

Hot work in pipe rack safety do’s and don’ts

Here is the safety dos and don’ts of precautions while performing hot work in pipe rack which can be shared with workers while conducing safety toolbox talk meeting.


  1. Mark the blind or line cut points on P&ID.
  2. Ensure positive isolation of the pipeline and put do not operate tag on each valve.
  3. Check the LEL level before begin the hot work.
  4. Drain and purge the pipeline thoroughly and follow LOTO.
  5. Identify specific hazards by making a field visit.
  6. Cover the Sewer manholes (AOC and COC) with fire blankets near or under hot work area.
  7. Mention all control measures in risk assessment or job safety analysis and enclosed it with work permit.
  8. Communicate safety control measures to all the personnel involved.
  9. Ensure fire registration of hot work permit and provide fire watcher.
  10. Provide appropriate access, egress and platform at all elevation.
  11. Use certified electrical equipment and ensure it's earthing.
  12. Make a hot work booth, keep fire water and extinguisher at place.
  13. Cover all the hydrocarbon line passes through nearby area with fire blanket.
  14. Cordon off the area and warn the people.
  15. Always hook lanyard to fixed supports, platform railings, or lifelines.
  16. Use fall protection equipment wherever necessary.
  17. Provide scaffold for work at height.
  18. Secured all tools while working at elevated platform.
  19. In the event of fire, evacuate the area immediately and assemble at assembly point.


  1. Don’t violate the safety conditions mentioned in hot work permit.
  2. Display the copy of hot work at workplace.
  3. Don’t start the hot work before testing the LEL level (gas test).
  4. Don’t perform do the welding and cutting on unidentified pipeline.
  5. Don’t carry out any maintenance work such as strainer cleaning or sampling of hydrocarbon near hot work.
  6. Don’t carry out spark test by electrode on the associated pipeline or workpiece.
  7. Don’t use pipeline or equipment or vessels as means of approach to work location.
  8. Don’t connect the return lead of welding machine to the charged hydrocarbon pipeline or scaffolding.
  9. Don’t carry out the grinding and welding outside the welding booth.
  10. Don’t left the site without switching off the welding machine and other equipment.
  11. Don’t violate with compliance of  PPE.
  12. Don’t throw any material from height, use rope to transport the equipment.

Performing hot work in pipe rack area is riskier job and must follow the robust safety precautions identified during the issue and receipt of the work permit. A job safety analysis must be carried out and the identified hazards and control measures must be communicated to the involved workers.

Safety Do’s and Don’ts are an excellent medium for sharing safety precautions with workers. This pipe rack hot work safety dos and don'ts can be shared with workers in the toolbox talk meeting.

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