SAFE WORK PROCEDURE

ForELECTRIC WELDING

Content: SWP and Training Plan for Electric WeldingPrepared by: XXXXXXXDate of initial implementation, Version 1: DD/MM/YYYYCurrent Revision No.: 1Date current version implemented: DD/MM/YYYYDate for next review: DD/MM/YYYY

XXXXXXX Pty Ltd | Safe Work Procedure – Electric Welding | Revision: XX | DD/MM/YYYY

PERSONAL PROTECTIVE EQUIPMENT TO BE UTILISED Safety eyewear & a welding helmet or hand shield with filter plate and cover plate is

mandatory. Hearing Protection. Fire retardant long sleeve coveralls and without cuffs, tears, rips, fraying or wear. Flameproof skullcap. Safety Boots. Specialty respirators for cutting hazardous materials. Flame proof gloves. Rubber gloves.

LICENSE / PERMIT / TRAINING REQUIRED Operators must have completed a training program recognised by XXXXXXXXX and be

authorised to perform this procedure.

START UP PROCEDUREBefore starting check that:

The work area is clear. Remove any trip hazards. There is adequate ventilation. You have easy access to a fire blanket and first aid kit.

DO NOT OPERATE UNSAFE MACHINERY. If the Welder is not in a safe operational condition, advise your supervisor or maintenance staff immediately.

OPERATIONAL PROCEDURE Because of their potentially explosive nature, do not attempt welding/cutting or hot work

to drums, barrels, tanks or other containers under any circumstances. Do not weld directly on a concrete floor. Heat from the arc can cause steam to build up

in the floor, which could cause an explosion.

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XXXXXXX Pty Ltd | Safe Work Procedure – Electric Welding | Revision: XX | DD/MM/YYYY

Position the welding cables to avoid sparks and molten metal coming into contact with them.

Keep cables free from grease and oil. Position the cables so they will not be driven or walked over. If the welding operation must be done on steel or other conductive material, an

insulating mat must be used under the operator. Electric welders can kill by electric shock.

If the welding area is wet or damp or the operator is actively perspiring then he/she should wear rubber gloves under the welding gloves.

Clean all metal to be welded by wire brushing or other methods. Protect your eyes and body from flying slag or chip when wire brushing the finished

bead or chipping slag. Do not leave unused electrodes or electrode stubs on the floor whereby they create a

slipping hazard. Hot metal should be handled with metal tongs or pliers. When quenching hot metal in water it should be done very carefully to avoid steam

burns. Any metal left to cool should be marked “HOT” with soapstone. The emergency switch should be located close to the operator. Welding should not be performed from ladders. “Welding in Progress” signs should be displayed in the area where welding is being

carried out.

CLOSEDOWN PROCEDURE Remove electrodes from the holders. Store holders away from accidental contact. Disconnect the welder from the power source. Clean the work area, remove all waste and secure any tools.

EMERGENCY PROCEDURE Hit the emergency stop button. Lock out the welder with a safety tag. Contact your supervisor immediately.

ADVISORY NOTESFire Prevention:The electric welder is capable of producing temperatures in excess of 3,000°Celcius. A safe workplace can be achieved by using metal or fire-resistant curtains as fire barriers. The floor should be concrete or another fire-resistant material. Cracks in the floor should be filled to prevent sparks and hot metal from entering.

When work cannot be moved to a fire-safe area then the area should be made safe by removing or protecting combustibles from the ignition source. In certain welding situations it may be necessary to ask someone to watch for fires that could go undetected until the welder has finished the job. Suitable fire extinguishing equipment such as buckets of sand or a dry chemical extinguisher, large enough for the situation, should be readily available.

Ventilation:

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XXXXXXX Pty Ltd | Safe Work Procedure – Electric Welding | Revision: XX | DD/MM/YYYY

The welder should be located in an area with adequate ventilation. In general, when welding is being done on metal not considered hazardous, a ventilation system that will move a minimum of 2000 cubic feet (200 cubic metres approx) per minute of air per welder is satisfactory. However many materials are considered very hazardous and should be welded only in adequately ventilated areas to prevent the accumulation of toxic materials or to eliminate possible oxygen deficiency not only to the operator, but to others in the immediate vicinity. Such ventilation should be provided by an exhaust system located as close to the work as possible.

When welding or cutting metal with hazardous coatings such as galvanised metal, the operator should use a supplied air type respirator or a respirator specially designed to filter the specific metal fume. Materials included in the very hazardous category are welding rod fluxes, coverings or other materials containing fluorine compounds, Zinc, Lead, Beryllium Cadmium and Mercury. Some cleaning and degreasing compounds combined with the metals they were cleaned with are also hazardous. Always follow the manufacturer’s precautions before welding or cutting in the presence of these materials.

IF YOU HAVE NOT BEEN TRAINED IN THE TASK OR YOU ARE NOT SURE HOW TO PERFORM THE TASK OR OPERATE THE MACHINERY, DO NOT OPERATE THE

MACHINERY AND ADVISE YOUR SUPERVISOR IMMEDIATELY.

OPERATOR’S STATEMENTI have been trained in and I understand this procedure.

I will perform my tasks to the best of my ability and in accordance with this safe working procedure.

Date: ..............................................................................................................................................

Operator’s Name: ..........................................................................................................................

Operator’s Signature: ....................................................................................................................

Witness Name: ...............................................................................................................................

Witness Signature: .........................................................................................................................

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ELECTRIC WELDING THEORY ASSESSMENT

Q1. Name at least five pieces of protective equipment to be utilised whilst Welding.

........................................................................................................................................................

Q2. Who is permitted to operate a Welder on this site?

........................................................................................................................................................

Q3. May the Welder be used if it has been isolated by tags or lockouts?

Yes No

Q4. What do you need to check each day before you start welding?

........................................................................................................................................................

Q5. Why can’t you weld directly onto a concrete floor?

........................................................................................................................................................

Q6. What precautions must be taken if there is moisture around the welding area or the operator is perspiring?

........................................................................................................................................................

Q7. What precautions must be taken with the cables?

........................................................................................................................................................

Q8. What must be done with unused and used electrodes at the completion of the job?

........................................................................................................................................................

Q9. What needs to be done to metal that has been left to cool?

........................................................................................................................................................

Q10. Where must the emergency switch be located during welding?

........................................................................................................................................................

Q11. What precautions are to be taken if welding directly onto steel or other conductive materials?

........................................................................................................................................................

Q12. Is it safe to weld from ladders?

Yes No

Q13. Is good ventilation important when welding?

Yes No

Q14. When quenching hot metal in water what must you be wary of?

........................................................................................................................................................

Employee signature: ......................................................................................................................

Questioned by: ...............................................................................................................................

Position/ Qualifications: ..................................................................................................................

Date:.....................

The staff member………………………………………… has successfully answered theoretical questions on the safe operation of Electric Welding

OBSERVATION OF ASSESSMENT

I have observed the employee ……………………………………. in a work situation and he/she has demonstrated competence in the practical aspects of the operation of an Electric Welder by following the Safe Work Procedure.

Signed: ..........................................................................................................................................

Name: .............................................................................................................................................

Position: ..........................................................................................................................................

Date: .........................................

Signed: ..........................................................................................................................................

Name: .............................................................................................................................................

Position: ..........................................................................................................................................

Date: .........................................

Signed: ..........................................................................................................................................

Name: .............................................................................................................................................

Position: ..........................................................................................................................................

Date: .........................................

SELF-ASSESSMENT – ELECTRIC WELDING TRAINING

Employee:.......................................................................................................................................

Trainer: ...........................................................................................................................................

Date: .........................................

I have received training in the following and understand (please initial):

YES NO

I must wear my eye, ear, foot protection, a welding mask, gloves and have my hair tied back and my shirt tucked in at all times. I must also wear a respiratory mask if I’m welding hazardous materials.

I must change this protective equipment when it wears out or is damaged.

I must carry out a pre-operational check including but not limited to: Safe starting and stopping procedures. Ensuring the machine is operating correctly. Ensuring access to fire blankets and suitable extinguishers and first

aid kits.

The immediate area must be clear and kept clear during the operations; including:

No persons in danger.

I must ensure that I: Not weld drums, tanks or barrels. Not weld directly onto a concrete floor. Position the cables so they are safe from sparks and slag. Keep the cables free from grease and oil. Use an insulating mat if welding on steel or other conductive

materials. Wear rubber gloves if sweating or there is moisture present at

the welding area. Protect my eyes from chips and slag when cleaning down the

job with a wire brush. Not leave spent electrodes lying around on the floor. Handle hot metal with tongs or pliers. Avoid being burnt by steam when quenching hot metal. Mark hot metal being left to cool. Not weld from ladders. Disconnect the welder from the power source when finished.

I have had the operation of Electric Welding demonstrated to me. I have had the opportunity to ask questions. I am aware that I can request further training at any time. I understand that by signing below; I agree to operate Electric Welding by following this Safe

Work Procedure.

Signed: ..........................................................................................................................................

Name: .............................................................................................................................................

Date: .........................................

ATTENDANCE REGISTER – ELECTRIC WELDING TRAINING

Trainer:............................................................................................................................................

Date: .........................................

NAME

ELECTRIC WELDING THEORY ASSESSMENT - ANSWERS

Q1. Name at least five pieces of protective equipment to be utilised whilst Welding.

A: Safety Eyewear (Brazing Goggles), Hearing, Boots, Hand Protection,Overalls, Leather apron, Ear protection, Face mask, Rubber Gloves, Respirators.

Q2. Who is permitted to operate a Welder on this site?

A: Only people who have successfully completed a training program and are authorised to do so.

Q3. May the Welder be used if it has been isolated by tags or lockouts?

Yes No

Q4. What do you need to check each day before you start welding?

A: Clear work area, ensure adequate ventilation, fire blanket and first aid kit handy.

Q5. Why can’t you weld directly onto a concrete floor?

A: Heat from the arc can heat up and explode.

Q6. What precautions must be taken if there is moisture around the welding area or the operator is perspiring?

A: Rubber gloves.

Q7. What precautions must be taken with the cables?

A: No oil and grease on them, position away from sparks and traffic.

Q8. What must be done with unused and used electrodes at the completion of the job?

A: Picked up off the floor.

Q9. What needs to be done to metal that has been left to cool?

A: Be marked as “HOT”.

Q10. Where must the emergency switch be located during welding?

A: Close to the operator.

Q11. What precautions are to be taken if welding directly onto steel or other conductive materials?

A: A rubber mat must be placed under the operator.

Q12. Is it safe to weld from ladders?

Yes No

Q13. Is good ventilation important when welding?

Yes No

Q14. When quenching hot metal in water what must you be wary of?

A: Burning yourself with steam.

SAFE WORK PROCEDURE – ELECTRIC WELDING

STARTUP PROCEDUREBefore starting check that: The work area is clear. Remove any trip

hazards. There is adequate ventilation. You have easy access to a fire blanket and

first aid kit.

CLOSEDOWN PROCEDURE Remove electrodes from the holders. Store holders away from accidental

contact. Disconnect the welder from the power

source. Clean the work area, remove all waste and

secure any tools.

EMERGENCY PROCEDURE Hit the emergency stop button. Lock out the welder with a safety tag. Contact your supervisor immediately.

Fire Prevention:When work cannot be moved to a fire-safe area then the area should be made safe by removing or protecting combustibles from the ignition source.

Ventilation:The welder should be located in an area with adequate ventilation. When welding or cutting metal with hazardous coatings such as galvanised metal, the operator should use a supplied air type respirator or a respirator specially designed to filter the specific metal fume

OPERATIONAL PROCEDURE Do not weld/cut or hot work drums, barrels,

tanks or other containers under any circumstances.

Do not weld directly on a concrete floor. Position the welding cables to avoid sparks

and molten metal coming into contact with them.

Keep cables free from grease and oil. Position the cables so they will not be

driven or walked over. If the welding operation must be done on

steel or other conductive material, an insulating mat must be used under the operator. Electric welders can kill by electric shock.

If the welding area is wet or damp or the operator is actively perspiring then he/she should wear rubber gloves under the welding gloves.

Clean all metal to be welded by wire brushing or other methods.

Protect your eyes and body from flying slag or chip when wire brushing the finished bead or chipping slag.

Do not leave unused electrodes or electrode stubs on the floor.

Hot metal should be handled with metal tongs or pliers.

Avoid steam burns when quenching hot metal in water.

Any metal left to cool should be marked “HOT” with soapstone.

The emergency switch should be located close to the operator.

Welding should not be performed from ladders.

“Welding in Progress” signs should be displayed in the area where welding is being carried out.

Failure to comply with the safety instructions may result in personal injury.

DO NOT OPERATE AN UNSAFE ELECTRIC WELDER