MEM05052A Apply Safe Welding Practices - Learner Guide

8/10/2019 MEM05052A Apply Safe Welding Practices - Learner Guide

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MEM05 Metal and Engineering

Training Package

Learner guide

Version 1

Training and Education Support

Industry Skills Unit

Meadowbank

Product Code: 5749

MEM05052AApply safe welding

practices


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TAFE NSW (Training & Education Support Industry Skills Unit, Meadowbank) 2013

MEM0 5 0 5 2 A A p p l y s a f e w e l d i n g p r a c t i ce s

AcknowledgmentsThe TAFE NSW Training and Education Support Industry Skills Unit, Meadowbankwould like to acknowledge the support and assistance of the following organisationsand people in the production of this learner guide.

CIGWELDBOC Gases AustraliaLincoln Electric Company (Australia)Silverwater Welding SuppliesWorkCover NSWSafe Work Australia

Writer:(Updated from existing TAFE Publications)

Reviewers:John Anderson (Hunter Institute)

Project Manager:Stephen DaviesEducation Programs ManagerTAFE NSW

EnquiriesEnquiries about this and other publications can be made to:

Training and Education Support Industry Skills Unit, Meadowbank Meadowbank TAFE

Level 3, Building J, See Street,

MEADOWBANK NSW 2114

Tel: 02-9942 3200 Fax: 02-9942 3257

TAFE NSW (Training and Education Support, Industry Skills UnitMeadowbank) 2012

Copyright of this material is reserved to TAFE NSW Training and EducationSupport, Industry Skills Unit Meadowbank. Reproduction or transmittal in whole

or in part, other than for the purposes of private study or research, and subject tothe provisions of the Copyright Act, is prohibited without the written authority ofTAFE NSW Training and Education Support, Industry Skills Unit Meadowbank.

ISBN 978-1-74236-458-2


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TAFE NSW (Training & Education Support Industry Skills Unit, Meadowbank) 2013


Table of Contents

Introduction ................................................................................... 7

1. General introduction ............................................................................. 7

2. Using this learner guide ......................................................................... 7

3. Prior knowledge and experience ............................................................. 9

4. Unit of competency overview ................................................................. 9

Topic 1: Interpreting work health and safety information ............ 13

Review questions ................................................................................... 23

Topic 2: Welding and thermal cutting hazards .............................. 25


Topic 3: Safe working practices .................................................... 41


Topic 4: Safe use and storage of gases ......................................... 59


Topic 5: Safety legislation ............................................................ 67


Topic 6: Safety tasks .................................................................... 75

Tasks 1: Develop and document an SOP for oxy acetylene welding ................ 76

Tasks 2: Develop and document an SWP for GMAW ..................................... 77

Tasks 3: Risk assessment for welding in a conned space............................ 79

Appendix 1: Material safety data sheets (MSDS) ........................... 83

Appendix 2: Guide to work health and safety act ......................... 95

Glossary and more information .................................................. 135

Resource Evaluation Form .......................................................... 137


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TAFE NSW (Training & Education Support, Industry Skills Unit Meadowbank) 2013 Page 13 of 140

Topic 1: Interpreting work health and safetyinformation

I n t r o d u c t i o n

Regulations have been introduced by the State Government to regulate work sitesto establish safe work conditions for workers and members of the community.Both the employee and employer have a direct responsibility to ensure safe workpractices are in place at all times otherwise the State Government Authority(WorkCover) can prosecute either or both for non-compliance.

Irrespective of nancial penalties, accidents and unsafe work conditions must beavoided at all times because everyone loses when an accident occurs. Accidentsoften result in pain and suffering or in worse case scenarios, loss of motor skills,sight, hearing, limbs or even death. Accidents are preventable provided approved

safe systems of work are followed and potential risks are eliminated or controlled.

For the employer, loss of production, medical expenses and increased insurancepremiums negatively impact on the protability of a company. For these reasons itis important that approved systems of work are implemented and that employeesare able to read, interpret and implement safety information. Remember, if youreunsure about a safety issue, stop and ask your teacher or workplace supervisor foradvice. Take no chances and protect your own safety and the safety of those aroundyou at all times.

W o r k , h e a l t h a n d s a f e t y

The Australian Government has in place national work, health and safety lawswhich is the Work Health and Safety (WHS) Act 2011 and the Work Health andSafety Regulations (2011). The WHS Act sets out the legal obligations that mustbe complied with in all states and territories to provide for the health and safety ofworkers.

The WHS act and regulations includes a list of commonsense objectives to helpfocus attention on sound workplace safety and welfare principles. The objectives ofthe WHS Act are to:

a. Secure and promote the health, safety and welfare of people at work.

b. Protect people in their place of work against risks to health or safety arising out

of the activities of others in the workplace.

c. Promote a safe and healthy work environment for people at work protectingthem from injury and illness.

d. Provide ways to allow consultation and cooperation to take place betweenemployers and employees to achieve the objectives of the WHS Act.

e. Ensure risks to health and safety in the workplace are identied, assessed andeliminated or controlled.


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f. Develop and promote community awareness of workplace health and safetyissues.

g. Provide a legislative framework to allow progressively higher standards of

workplace health and safety to occur taking into account changes in technologyand work practices.

h. Deal with the impact of particular classes / types of dangerous goods and plantin the workplace and beyond places of work.

The Work, Health and Safety Act and Regulations (2011) and other importantinformation and guidance are available from the WorkCover Authority of New SouthWales or Safe Work Australia websites as indicated below.

www.workcover.nsw.gov.auwww.safeworkaustralia.gov.au/sites/SWA/Pages/default.aspx

S it e i n d u c t i o n

Workplaces are obliged to provide employees and visitors to the site with a siteinduction to ensure people understand the following requirements:

The nature of the operation

Safety rules applicable to the work site

Signing in/out procedures

Go and no go areas

Personal protective equipment safety

Emergency procedures.

Building sites have an added obligation, anyone entering the site must have aCo n s t r u c t i o n I n d u c t i o n Ca r d that provides proof that the person has successfullycompleted a general construction induction training program.

General construction induction training provides workers with an awareness andunderstanding of:

Their rights and responsibilities in relation to WHS laws

Common hazards and risks in the construction industry

Basic risk management principles

Standard of behavior expected of workers on construction sites.

In addition, workplaces need to be managed to ensure workers on site are givenclear directions on what to do in the event of a re or other emergency. This iscalled an evacuation plan and clearly sets out how personnel will be alerted, anevacuation procedure and a designated assembly location.


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I n d u c t i o n c ar d

St a n d a r d s A u s t r a l ia

Standards Australia is an independent organisation recognised by the AustralianGovernment as the peak non-government body responsible for meeting Australia'sneed for developing contemporary and internationally aligned Standards and relatedservices.

Standards are published documents setting out specications and procedures toensure products, services and systems are safe, reliable and perform the way theywere intended to. Standards are designed to provide a common language to dene/specify quality and safety requirements. Standards are used as guidance documentsfor industry and include:

Australian Standards International Standards and Joint Standards Codes Specications Handbooks Guidelines.

The above documents are practical and are based on sound industrial, scienticand consumer experience. They are constantly reviewed and updated by technicalcommittees to ensure they keep pace with new technologies, materials, industrypractices and relevant legislation.

Australian Standards are widely used in the fabrication industry. Typical publications

developed to assist industry operate efciently and safely include:

AS 1674.1 - Safety in welding and allied processes AS 3853.1 - Health and safety in welding and allied processes - Sampling of

airborne particles and gases in the operators breathing zone - Sampling ofairborne particles

AS 2812 - Welding, brazing and cutting of metals - Glossary of terms AS 4603 - Flashback arresters - Safety devices for use with fuel gases and

oxygen or compressed air AS 1674 - Safety in welding and allied processes Electrical.

The above Standards are typical examples of those developed to provide guidanceand safety advice to people working in welding and allied industries. It is important


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that individuals and enterprises interpret and implement relevant informationcontained in these documents.

In addition to the above, there are Standards for the manufacture and testing of

pressure vessels, welding of structural steelwork, welding consumables, equipmentquality and numerous others. Typical examples include:

AS 1796 Certication of Welders and Welding Supervisors AS/NZS 1554 Welding of Steel Structures AS 4458 Pressure Equipment Manufacture AS/NZS 4855 Welding consumables - Covered electrodes for manual metal arc

welding of non-alloy and ne grain steels Classication AS 4882 Shielding gases for welding AS/NZS 1167 Welding and brazing - Filler metals - Filler metal for welding

It is important for welding operators to have a reasonable awareness and

understanding of Standards relevant to their workplace and job role and if required,search for relevant information to ensure they comply with safe practices andapproved work procedures. For further information on Australian Standards go to:www.standards.com.au

W o r k m e t h o d st a t em e n t s

A work method statement (WMS) is a set of instructions setting out what thejob is and how it is to be performed. From a welding perspective, it will includea weld procedure detailing the essential requirements and variables needed toproduce acceptable quality welds. For example, this would include type and sizeof consumables, current, voltage, travel speed settings and any pre or post-heattreatment requirements.

An extension of a WMS is a Safe Work Method Statement (SWMS). A safe workmethod statement is a document that details the task, procedure by which it isto be performed, potential hazards and safety controls to be put in to place tocomplete the task.

SWMS documents are normally endorsed and signed by a Responsible Ofcer,often the workplace supervisor and/or safety ofcer. This document is signed bythe employee(s) undertaking the task to show they have read and understoodthe directions and instructions relating to the activity.

Note:States and territories may use different terms to describe a Safe Work

Method Statement. For example job safety analysis (JSA) or job safety andenvironment analysis (JSEA) are sometimes used for the same purpose. Thesedocuments have to be nalised by a risk assessment evaluation and specify therules workers undertaking the task must comply with.

No fabrication or welding work is permitted in a hazardous location or connedspace without completion of a risk assessment and written authorisation by aResponsible Ofcer for the work to take place. This is discussed in more detail intopic 2.


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Sa f e o p e r a t i n g p r o c e d u r e

Machinery can be dangerous and accidents can happen if:

Guarding is inadequate Machine/equipment is faulty

Operators are not properly trained

Operators do not follow approved operational procedures.

To reduce the risk of accidents it is mandatory that a safe operating procedure (SOP)be clearly placed on a machine, preferably in full view of the operator to read anddigest before starting the machine.

An SOP is a written document that clearly states the key hazards/risks associatedusing a machine or process. An SOP must provide instructions for a given task

stating the preferred and safest method of performing it in a standardised manner.SOPs must be reviewed and approved (validated) by a Responsible Ofcerwithinthe organisation. Employees are obligated to follow SOP directions.

The purpose and objectives of using SOPs in the workplace is to:

1. Provide a check to see if employees are working safely.2. Remind employees not to take short cuts as they can lead to accidents.3. Inform employees the employer is serious about safety in the workplace.

Note:Do not use equipment or machinery unless you have received training andcan demonstrate you can operate it safely. A typical SOP for a bench drill is shownon page 18.

Sa f e w o r k p r o c ed u r e ( SW P )

A SWP is more detailed document outlying the risks associated with a task andincorporating appropriate control measures into a sequence of steps for performingthe task safely.

This type of document is most effective when developed in consultation with otherworkers and approved by a Responsible Ofcer.SWPs provide a useful tool fortraining and supervising workers, and responding to incident reports and changes inthe workplace. A typical SWP for operating a pedestal drill is shown on page 19.


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SOP001

SAFE OPERATING PROCEDURE (SOP)

BENCH DRILL

Developed by: ____________________ Date: _________________________

Validated by: _____________________ Date: __________________________

Review date: _____________________

Personal protective equipment

H a z ar d s / R is k s :

Hot and sharp swarf injuring hands and/or eyes Drill bit breaking causing eye and/or body injuries Loose clothing and/or hair being caught by swarf or drill chuck Chuck key left in chuck Cuts to hands from sharp burrs Job moving, vice not secure Skin contact with cutting uid Manual handling.

P r o c e d u r e :

Inspect work area and drill Select required drill speed

Fit drill bit Secure workpiece Switch on drill Perform required task Switch off drill Clean up work area.

REPORT ALL FAULTS IMMEDIATELY TO SUPERVISOR

T y p i c a l SOP


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SWP001

SAFE WORK PROCEDURE (SWP)

PEDESTAL DRILL

Developed by: ____________________ Date: _________________________

Validated by: _____________________ Date: __________________________

Review date: _____________________________________________________

Personal protective equipment

Hazards/Risks

Hot and sharp swarf injuring hands and/or eyes Drill bit breaking causing eye and/or body injuries Loose clothing and/or hair being caught by swarf or drill chuck Chuck key left in chuck Cuts to hands from sharp burrs Job moving, vice not secure Skin contact with cutting uid Manual handling.

Before operating

Inspect work area and drill

Ensure the work area is clear of clutter Isolate and tag drill No gloves, loose clothing or jewellery to be worn while working on or near

rotating equipment Long hair must be covered

Visually inspect drill (chuck, hand feed lever, vice etc.) Any visual faults-afx danger tag to drill and immediately advise the

supervisor Know the location of the emergency stop button before proceeding.

Select drill speed

Make sure drill is isolated Lift the pulley cover and adjust V belt to provide required speed


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Fit drill bit

Make sure drill is isolated Insert the correct drill bit into the chuck and tighten with the chuck key

Remove the chuck key For more tapered drills - securely t drill into the drill spindle

Secure work

Make sure drill is isolated Place the item to be drilled in vice and tighten Adjust vice table to the required height Secure loose clothing and cover long hair.

When operating

Start up Wear safety goggles or glasses Ensure the work area is clear Check the drill bit and workpiece are aligned Switch on the drill Check the drill bit is running true.

Drilling

Apply pressure to the hand feed lever maintain a steady pressure until thedrill is about to break through the other side of the workpiece

Reduce pressure to prevent drill bit from grabbing

Shavings should be kept to a minimum length by regularly clearing the drill bit Use appropriate cutting uid if required (see supervisor) Be aware of hot metal swarf On completion of the task switch off the drill.

After use

Clean up

Drill must be turned off at the isolating switch and tagged before cleaning Clean drill and adjacent work area Use a brush to remove metal swarf

Dispose of scrap/swarf in appropriate receptacle.

Servicing

Drill must be turned off at the isolating switch and tagged before servicing Carry out service as per maintenance schedule Enter service data into equipment log.

REPORT ALL FAULTS IMMEDIATELY TO SUPERVISOR

T y p i c a l SW P


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R is k a s s e ssm e n t

A risk assessment involves:

Identifying a hazard(s) Assessing the risk associated with that hazard to avoid harm Determining ways to eliminate or control the hazard(s) Monitoring and reviewing the controls you have in place on a regular basis.

In practical terms, a risk assessment involves taking a detailed look at yourworkplace to identify things, situations, processes, etc that may have potential tocause harm, particularly to people. After identifying possible hazards and risks youevaluate how likely and severe the risks is and then decide what measures to taketo prevent or control the harm from happening.

Everyone in the workplace is responsible for setting safe working procedures toensure the health and wellbeing of all personnel (employees, cleaners, visitors,

contractors, the public, etc). It is generally acknowledged injuries in the workplaceare a result of one or more of the following:

Failure to identify a hazard(s) Failure to avoid or minimise the hazard(s) Not understanding the nature of materials or substances being used (see MSDS) Poor application of safety precautions Inappropriate or poorly maintained plant or equipment Lack of knowledge or training Poor work procedures Lack of adequate supervision.

Various matrixs and grid tables have been designed to help identify and determinethe likelihood and consequence (level of risk) associated with a given activity. Oncethe level of risk has been determined, a decision needs to be made to whether thelevel of risk is acceptable or not.

With the aid of a typical grid or table, as shown on page 22 we can allocatea numerical ranking (i.e. 1 to 6) to indicate the level of risk. Using this riskassessment model we can say the lower the number the higherthe risk factor.

Example 1: using the matrix table on page 22, if a risk is ranked at say 6, we cansay:

The probability of it causing severe injury or illness is very unlikelyand How severely could it hurt someone or how ill could it make them may result in

only needing First aid.

Example 2: if a risk is ranked at say 2, we can say:

The probability of causing severe injury or illness is Likelyand How severely could it hurt someone or how ill could it make them may result in

Long-term illness or serious injury.

Once a risk assessment is completed an appropriate safe system of work andcontrols will need to be determined to make the activity (job) as safe as possible.


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How severelycould it hurtsomeoneor how ill

could it makethem?

Probability to cause severe injury or illness?

Very likely

Could happenany time

Likely

Could happenat some time

Unlikely

Could happenbut very rarely

Very unlikely

Could happenbut probably

never will

Kill or causepermanentdisability orinjury

1 1 2 3

Long termillness orserious injury

1 2 3 4

Lost timeinjury 2 2 4 5

First aidneeded 3 4 5 6

R is k a ss e ss m e n t g r i d / t a b l e

Ma t e r i a l s a f e t y d a t a s h e e t ( MSDS)

An MSDS is a document containing detailed information about the health hazardsassociated with the material or substance you are using and recommended safework practices. An MSDS is intended to provide workers and emergency personnelwith approved procedures for handling or working with the material or substance ina safe manner. Typical information found on MSDS include:

The products name Chemical and generic name of ingredients in the material Physical and chemical data of the substance/material Handling and storage details Health hazard information Precautions for safe use and handling First aid Date the MSDS was prepared Manufacturer's or importer's name, Australian address and telephone number

etc.

It is important that everyone in the workplace knows how to read and interpret a

MSDS. An MSDS is available for materials, welding products and consumables onthe market and available from the maker or supplier of the product. Material SafetyData Sheets are typically available for:

Gases Flux covered and ux cored electrodes Chemical uxes Tungsten electrodes Filler rods GMAW wires Coated materials containing zinc, zincalume, cadmium, chromium, nickel etc Metal cleaning and passivation chemicals.

MSDS sheets for welding consumables are shown in detail in Appendix 1.


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Review questions

These questions have been included to help you revise what you have learnt in

Topic 1: Interpreting work health and safety information.

1. What instrument is in place to protect the health and safety of workers acrossAustralia.

______________________________________________________________

______________________________________________________________

2. State the name of the NSW Government Authority set up to regulate andoversee safe working conditions.

______________________________________________________________

3. What detailed document is used to describe a work task and how it is to becompleted?

______________________________________________________________

______________________________________________________________

4. Name the peak non-government body charged with developing and publishing

technical, safety and quality requirements for industry to work to.

______________________________________________________________

5. List three(3) items of information workers can expect to receive as part of aworkplace induction.

______________________________________________________________

______________________________________________________________

______________________________________________________________

6. List four (4) typical causes of injuries in the workplace.

______________________________________________________________

______________________________________________________________

______________________________________________________________

______________________________________________________________

Documents

MEM05052A Apply Safe Welding Practices - Learner Guide