SAMPLE. MEM05052A Apply safe welding practices. MEM05 Metal and Engineering Training Package. Learner guide Version 1

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1 MEM05 Metal and Engineering Training Package MEM05052A Apply safe welding practices Learner guide Version 1 Training and Education Support Industry Skills Unit Meadowbank Product Code: 5749

2 Acknowledgments The TAFE NSW Training and Education Support Industry Skills Unit, Meadowbank would like to acknowledge the support and assistance of the following organisations and people in the production of this learner guide. CIGWELD BOC Gases Australia Lincoln Electric Company (Australia) Silverwater Welding Supplies WorkCover NSW Safe Work Australia Writer: (Updated from existing TAFE Publications) Reviewers: John Anderson (Hunter Institute) Project Manager: Stephen Davies Education Programs Manager TAFE NSW Enquiries Enquiries 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: Fax: TAFE NSW (Training and Education Support, Industry Skills Unit Meadowbank) 2012 Copyright of this material is reserved to TAFE NSW Training and Education Support, Industry Skills Unit Meadowbank. Reproduction or transmittal in whole or in part, other than for the purposes of private study or research, and subject to the provisions of the Copyright Act, is prohibited without the written authority of TAFE NSW Training and Education Support, Industry Skills Unit Meadowbank. ISBN TAFE NSW (Training & Education Support Industry Skills Unit, Meadowbank) 2013

3 Table of Contents Introduction General introduction Using this learner guide Prior knowledge and experience Unit of competency overview... 9 Topic 1: Interpreting work health and safety information Review questions Topic 2: Welding and thermal cutting hazards Review questions Topic 3: Safe working practices Review questions Topic 4: Safe use and storage of gases Review questions Topic 5: Safety legislation Review questions Topic 6: Safety tasks Tasks 1: Develop and document an SOP for oxy acetylene welding Tasks 2: Develop and document an SWP for GMAW Tasks 3: Risk assessment for welding in a confined space Appendix 1: Material safety data sheets (MSDS) Appendix 2: Guide to work health and safety act Glossary and more information Resource Evaluation Form TAFE NSW (Training & Education Support Industry Skills Unit, Meadowbank) 2013

4 Topic 1: Interpreting work health and safety information Introduction Regulations have been introduced by the State Government to regulate work sites to establish safe work conditions for workers and members of the community. Both the employee and employer have a direct responsibility to ensure safe work practices are in place at all times otherwise the State Government Authority (WorkCover) can prosecute either or both for non-compliance. Irrespective of financial penalties, accidents and unsafe work conditions must be avoided at all times because everyone loses when an accident occurs. Accidents often 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 insurance premiums negatively impact on the profitability of a company. For these reasons it is important that approved systems of work are implemented and that employees are able to read, interpret and implement safety information. Remember, if you re unsure about a safety issue, stop and ask your teacher or workplace supervisor for advice. Take no chances and protect your own safety and the safety of those around you at all times. Work, health and safety The Australian Government has in place national work, health and safety laws which is the Work Health and Safety (WHS) Act 2011 and the Work Health and Safety Regulations (2011). The WHS Act sets out the legal obligations that must be complied with in all states and territories to provide for the health and safety of workers. The WHS act and regulations includes a list of commonsense objectives to help focus attention on sound workplace safety and welfare principles. The objectives of the 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 protecting them from injury and illness. d. Provide ways to allow consultation and cooperation to take place between employers and employees to achieve the objectives of the WHS Act. e. Ensure risks to health and safety in the workplace are identified, assessed and eliminated or controlled. TAFE NSW (Training & Education Support, Industry Skills Unit Meadowbank) 2013 Page 13 of 140

5 f. Develop and promote community awareness of workplace health and safety issues. g. Provide a legislative framework to allow progressively higher standards of workplace health and safety to occur taking into account changes in technology and work practices. h. Deal with the impact of particular classes / types of dangerous goods and plant in the workplace and beyond places of work. The Work, Health and Safety Act and Regulations (2011) and other important information and guidance are available from the WorkCover Authority of New South Wales or Safe Work Australia websites as indicated below. Site induction Workplaces are obliged to provide employees and visitors to the site with a site induction 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 a Construction Induction Card that provides proof that the person has successfully completed a general construction induction training program. General construction induction training provides workers with an awareness and understanding 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 given clear directions on what to do in the event of a fire or other emergency. This is called an evacuation plan and clearly sets out how personnel will be alerted, an evacuation procedure and a designated assembly location. Page 14 of 140 TAFE NSW (Training & Education Support, Industry Skills Unit Meadowbank) 2013

6 Standards Australia Induction card Standards Australia is an independent organisation recognised by the Australian Government as the peak non-government body responsible for meeting Australia's need for developing contemporary and internationally aligned Standards and related services. Standards are published documents setting out specifications and procedures to ensure products, services and systems are safe, reliable and perform the way they were intended to. Standards are designed to provide a common language to define/ specify quality and safety requirements. Standards are used as guidance documents for industry and include: Australian Standards International Standards and Joint Standards Codes Specifications Handbooks Guidelines. The above documents are practical and are based on sound industrial, scientific and consumer experience. They are constantly reviewed and updated by technical committees to ensure they keep pace with new technologies, materials, industry practices and relevant legislation. Australian Standards are widely used in the fabrication industry. Typical publications developed to assist industry operate efficiently and safely include: AS Safety in welding and allied processes AS Health and safety in welding and allied processes - Sampling of airborne particles and gases in the operators breathing zone - Sampling of airborne particles AS Welding, brazing and cutting of metals - Glossary of terms AS Flashback arresters - Safety devices for use with fuel gases and oxygen or compressed air AS Safety in welding and allied processes Electrical. The above Standards are typical examples of those developed to provide guidance and safety advice to people working in welding and allied industries. It is important TAFE NSW (Training & Education Support, Industry Skills Unit Meadowbank) 2013 Page 15 of 140

7 that individuals and enterprises interpret and implement relevant information contained 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, equipment quality and numerous others. Typical examples include: AS 1796 Certification 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 fine grain steels Classification 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 and approved work procedures. For further information on Australian Standards go to: Work method statements A work method statement (WMS) is a set of instructions setting out what the job is and how it is to be performed. From a welding perspective, it will include a weld procedure detailing the essential requirements and variables needed to produce acceptable quality welds. For example, this would include type and size of consumables, current, voltage, travel speed settings and any pre or post-heat treatment requirements. An extension of a WMS is a Safe Work Method Statement (SWMS). A safe work method statement is a document that details the task, procedure by which it is to be performed, potential hazards and safety controls to be put in to place to complete the task. SWMS documents are normally endorsed and signed by a Responsible Officer, often the workplace supervisor and/or safety officer. This document is signed by the employee(s) undertaking the task to show they have read and understood the 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 and environment analysis (JSEA) are sometimes used for the same purpose. These documents have to be finalised by a risk assessment evaluation and specify the rules workers undertaking the task must comply with. No fabrication or welding work is permitted in a hazardous location or confined space without completion of a risk assessment and written authorisation by a Responsible Officer for the work to take place. This is discussed in more detail in topic 2. Page 16 of 140 TAFE NSW (Training & Education Support, Industry Skills Unit Meadowbank) 2013

8 Safe operating procedure 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 and digest before starting the machine. An SOP is a written document that clearly states the key hazards/risks associated using 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 Officer within the 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 and can demonstrate you can operate it safely. A typical SOP for a bench drill is shown on page 18. Safe work procedure (SWP) A SWP is more detailed document outlying the risks associated with a task and incorporating appropriate control measures into a sequence of steps for performing the task safely. This type of document is most effective when developed in consultation with other workers and approved by a Responsible Officer. SWPs provide a useful tool for training and supervising workers, and responding to incident reports and changes in the workplace. A typical SWP for operating a pedestal drill is shown on page 19. TAFE NSW (Training & Education Support, Industry Skills Unit Meadowbank) 2013 Page 17 of 140

9 SOP 001 SAFE OPERATING PROCEDURE (SOP) BENCH 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 fluid Manual handling. Procedure: 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 Typical SOP Page 18 of 140 TAFE NSW (Training & Education Support, Industry Skills Unit Meadowbank) 2013

10 SWP 001 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 fluid 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-affix 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 TAFE NSW (Training & Education Support, Industry Skills Unit Meadowbank) 2013 Page 19 of 140

11 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 fit 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 the drill 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 fluid 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 Typical SWP Page 20 of 140 TAFE NSW (Training & Education Support, Industry Skills Unit Meadowbank) 2013

12 Risk assessment 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 your workplace to identify things, situations, processes, etc that may have potential to cause harm, particularly to people. After identifying possible hazards and risks you evaluate how likely and severe the risks is and then decide what measures to take to prevent or control the harm from happening. Everyone in the workplace is responsible for setting safe working procedures to ensure the health and wellbeing of all personnel (employees, cleaners, visitors, contractors, the public, etc). It is generally acknowledged injuries in the workplace are 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 matrix s and grid tables have been designed to help identify and determine the likelihood and consequence (level of risk) associated with a given activity. Once the level of risk has been determined, a decision needs to be made to whether the level of risk is acceptable or not. With the aid of a typical grid or table, as shown on page 22 we can allocate a numerical ranking (i.e. 1 to 6) to indicate the level of risk. Using this risk assessment model we can say the lower the number the higher the risk factor. Example 1: using the matrix table on page 22, if a risk is ranked at say 6, we can say: The probability of it causing severe injury or illness is very unlikely and 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 Likely and 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 and controls will need to be determined to make the activity (job) as safe as possible. TAFE NSW (Training & Education Support, Industry Skills Unit Meadowbank) 2013 Page 21 of 140

13 How severely could it hurt someone or how ill could it make them? Kill or cause permanent disability or injury Long term illness or serious injury Very likely Could happen any time Probability to cause severe injury or illness? Likely Could happen at some time Unlikely Could happen but very rarely Very unlikely Could happen but probably never will Lost time injury First aid needed Risk assessment grid/table Material safety data sheet (MSDS) An MSDS is a document containing detailed information about the health hazards associated with the material or substance you are using and recommended safe work practices. An MSDS is intended to provide workers and emergency personnel with approved procedures for handling or working with the material or substance in a safe manner. Typical information found on MSDS include: The product s 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 on the market and available from the maker or supplier of the product. Material Safety Data Sheets are typically available for: Gases Flux covered and flux cored electrodes Chemical fluxes 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. Page 22 of 140 TAFE NSW (Training & Education Support, Industry Skills Unit Meadowbank) 2013

14 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 across Australia. 2. State the name of the NSW Government Authority set up to regulate and oversee safe working conditions. 3. What detailed document is used to describe a work task and how it is to be completed? 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 a workplace induction. 6. List four (4) typical causes of injuries in the workplace. TAFE NSW (Training & Education Support, Industry Skills Unit Meadowbank) 2013 Page 23 of 140