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Safe Work Instruction 02 Boiler making/Welding/Grinding

Task Hazard/Energy
No Control measures or action required
& Potential Hazards

1 Access & Setup Uneven surfaces, material in area Use correct paths to access work fronts
Remove excess materials in area
Dispose of unwanted materials
Notify supervisor if remediation work is required
Weather affected surface (erosion, water, dust) Avoid walking through excessively affected wet areas
Notify supervision if potholes and erosion requires rectification and make area safe before leaving
Stairs Use three points of contact when using stairs
Walk up ladders forward facing
Varying ground levels Use designated paths where provided
Ensure surface is in a satisfactory state to be used as access, if not notify supervisor
Damaged/faulty equipment Pre start checks on all machinery, electrical tooling and equipment
Ensure guards are in place and serviceable
Electrical faults Self test RCDs
Elevate leads or protect from damage
Protect electrical equipment from conductive material (water, steel work, dampness)
Ensure equipment has current electrical test tag
Ensure VRDs are operational where required
2 Cutting and welding Sparks, Burns and Fire Correct PPE for all tasks (i.e. appropriate gloves, double eye protection, non flammable clothing, welding jacket)
Ensure hot works permits are in place
Protect equipment from damage using blankets and tarps
Barricade areas off below work areas
Elevate electrical and welding leads away from hot slag, sparks, hot metal
Ensure fire extinguisher is available, charged, serviceable and within 6 monthly inspection period
Remove all combustible material from immediate work area and areas where hot work will affect
Ensure housekeeping is maintain throughout task
Use welding screens where possible to contain flashes and sparks
Angle grinding Use grinder handle
Use two hands on grinder
Secure work piece before starting
Ensure guard is in good condition
Ensure power is disconnected when changing discs
Do not use discs for any other purpose than what they are intended for
Noise Use Class 5 hearing protection as a minimum
Eye injuries Double eye protection must be worn as a minimum
Dropped objects Use tool and equipment lanyards where required
Barricade area below where there is a risk of dropped objects
Ensure information tags are placed on barricading
Arc Flashes Correct PPE for all tasks (i.e. Welding hood, double eye protection, non flammable clothing, welding jacket)
Electric Shock Consider welding categories
Safe Work Instruction 02 Boiler making/Welding/Grinding

Task Hazard/Energy
No Control measures or action required
& Potential Hazards

Separate yourself from the work piece using welding jacket, gloves, plywood, blankets and tarps
Self test RCDs
Ensure VRDs are operational where required
Earth clamp is to be positioned as close as practical to the work piece
Repairs of associated equipment shall be done at the stores
All PPE must be dry and in good condition
Welding machine shall be de-energised when changing MMWA leads
Welding machine shall not be left on when unattended
Do not weld in wet conditions
Cuts from metal and the use of equipment Use the correct type of gloves for the task
Manual Handling Injuries Use correct lifting techniques when lifting, shift or moving equipment and materials
Plan all manual handling lifts (path to be travelled, within personal capabilities)
Do not over exert by pushing or pulling material
Dual person lift where required
Use mechanical aides where possible
Weather conditions and ambient temperature Keep hydrated throughout task
Do not weld in rain or wet conditions
3 Oxy Cutting/Propane Heating Flash back Ensure arrestors are fitted to the handpiece and at the bottle
Inspect equipment before use
Wear correct PPE (double eye protection, suitable gloves, welding jacket)
Fire and heat Protect equipment from damage using blankets
Barricade areas off below work areas
Elevate electrical and welding leads away from hot slag, hot metal
Ensure fire extinguisher is available, charged, serviceable and within 6 monthly inspection period
Remove all combustible material from immediate work area and areas where hot work will affect
Ensure housekeeping is maintain throughout task
4 Bending Pipes Crushing injuries Ensure personnel are competent in use of bending machine
Hands and body parts to be kept clear of pinch points and crush points
Use two people where required (one to hold pipe, one to operate machine)
Safe Work Instruction 02 Boiler making/Welding/Grinding

Task Hazard/Energy
No Control measures or action required
& Potential Hazards