MEM05052A Apply Safe Welding Practices

MEM05 Metal and Engineering
Training Package
PL
MEM05052A
Apply safe welding
practices
Learner guide
SA
M
Version 1
Training and Education Support

Industry Skills Unit
Meadowbank
Product Code: 5749
MEM05052A Apply safe welding practices
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)
Enquiries
PL
Stephen Davies
Education Programs Manager
TAFE NSW
Project Manager:
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
SA
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Tel: 02-9942 3200
Fax: 02-9942 3257
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 978-1-74236-458-2
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

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

Topic 5: Safety legislation............................................................. 67
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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 confined 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
TAFE NSW (Training & Education Support Industry Skills Unit, Meadowbank) 2013
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.
PL
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 youre
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
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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
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.
www.workcover.nsw.gov.au
www.safeworkaustralia.gov.au/sites/SWA/Pages/default.aspx
Site induction
The nature of the operation
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Workplaces are obliged to provide employees and visitors to the site with a site
induction to ensure people understand the following requirements:
Safety rules applicable to the work site

Signing in/out procedures
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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&EducationSupport,IndustrySkillsUnitMeadowbank)2013
Induction card
Standards Australia
PL
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.
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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 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 of
airborne 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 guidance
and safety advice to people working in welding and allied industries. It is important
Page 15 of 140
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
PL
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:
www.standards.com.au
Work method statements
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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
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:
PL
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.
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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.
Page 17 of 140
SOP
001
SAFE OPERATING PROCEDURE (SOP)

BENCH DRILL
Developed by: ____________________ Date: _________________________

Validated by: _____________________ Date: __________________________
Review date: _____________________
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.
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Personal protective equipment
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
SWP
001
SAFE WORK PROCEDURE (SWP)

PEDESTAL DRILL
Developed by: ____________________ Date: _________________________

Validated by: _____________________ Date: __________________________
Review date: _____________________________________________________
Personal protective equipment
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.
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Hazards/Risks
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
Page 19 of 140
Fit

drill bit
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
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
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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.
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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
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.
PL
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.
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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:
Various matrixs 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.
Page 21 of 140
How severely
could it hurt
someone
or how ill
could it make
them?
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
Kill or cause
permanent
disability or
injury
Long term
illness or
serious injury
Lost time
injury
First aid
needed
Very likely
Could happen
any time
Risk assessment grid/table
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Material safety data sheet (MSDS)
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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 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 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
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.
_______________________________________________________________
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3. What detailed document is used to describe a work task and how it is to be

completed?
_______________________________________________________________
_______________________________________________________________
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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.
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
Page 23 of 140

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MEM05 Metal and Engineering

Training and Education Support

Product Code: 5749

(Updated from existing TAFE Publications)

John Anderson (Hunter Institute)

Enquiries about this and other publications can be made to:

Training and Education Support Industry Skills Unit, Meadowbank

Tel: 02-9942 3200

Fax: 02-9942 3257

TAFE NSW (Training and Education Support, Industry Skills Unit

MEM05052A Apply safe welding practices

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

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

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

MEM05052A Apply safe welding practices

Topic 1: Interpreting work health and safety

Work, health and safety

MEM05052A Apply safe welding practices

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

The nature of the operation

Safety rules applicable to the work site

Personal protective equipment safety

MEM05052A Apply safe welding practices

Standards Australia is an independent organisation recognised by the Australian

MEM05052A Apply safe welding practices

that individuals and enterprises interpret and implement relevant information

AS 1796 Certification of Welders and Welding Supervisors

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

Work method statements

MEM05052A Apply safe welding practices

Safe operating procedure

1. Provide a check to see if employees are working safely.

Safe work procedure (SWP)

MEM05052A Apply safe welding practices

SAFE OPERATING PROCEDURE (SOP)

Developed by: ____________________ Date: _________________________

Hot and sharp swarf injuring hands and/or eyes

Personal protective equipment

Inspect work area and drill

REPORT ALL FAULTS IMMEDIATELY TO SUPERVISOR

MEM05052A Apply safe welding practices

SAFE WORK PROCEDURE (SWP)

Developed by: ____________________ Date: _________________________

Personal protective equipment

Hot and sharp swarf injuring hands and/or eyes

Inspect work area and drill

MEM05052A Apply safe welding practices

REPORT ALL FAULTS IMMEDIATELY TO SUPERVISOR

MEM05052A Apply safe welding practices

In practical terms, a risk assessment involves taking a detailed look at your

Failure to identify a hazard(s)

Everyone in the workplace is responsible for setting safe working procedures to

MEM05052A Apply safe welding practices

Probability to cause severe injury or illness?

Risk assessment grid/table

Material safety data sheet (MSDS)

An MSDS is a document containing detailed information about the health hazards

MEM05052A Apply safe welding practices

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

Developed by: Date: _____

Developed by: Date: _____