General Health and Safety Whole workshop – Electric shock from machinery, guards and fences on

machinery correctly set, machinery used at correct speed settings, Loose clothing not worn, jewellery
removed, eye protection (goggles) worn when working, ventilation, extraction, equipment properly
adjusted / used when working & emergency stop locations in the workshop. Workshop rules and
behaviour (safe working practice).  Aprons and Goggles must be worn at all times when using
machinery.  Loose hair tied back and jewellery taken off. Shirt / pullover sleeves pulled up.  Know
where the Emergency stops are - locations within the room.  Workshops should be kept clean and tidy.
Scrap material should be put in bins.  Never run in a workshop.  Stools under desks if practical work is
being undertaken.  Never blow dust – sweep into a bin.  Excess tools and materials put away after use.
Carrying tools the correct way.  Main risk when people do not know or understand how to use
something correctly – if not sure always ask.

Grinding Machines RISK LEVEL MID Hazards

 Over speeding, damaged or incorrectly mounted abrasive wheels can break while rotating and be
violently ejected from the grinding machine.

 Contact with the wheel can cause cuts.

 Long hair and loose clothing can become entangled in moving parts of the machine.

 Work pieces can be violently ejected.

 Fingers or work pieces can be ejected from the machine. Sharp edges can cause cuts.

 Hot work pieces can cause burns.

 Grinding machines can present a hazard of electrical shock. Inadvertent starting of the machine can
present a hazard. Dust can be inhaled.

Lack of space around the machine can lead to the operator being pushed by passers-by.

Risk Control Measures

 A means of electrical isolation using a fused switch-disconnector on or adjustment to the machine, and
that it is controlled by a starter incorporating overload protection.

 A conveniently positioned mushroom headed stop button or other suitable control device that can
quickly stop the machine in an emergency.

 There should be sufficient space around the machine to prevent the operator from being accidentally
pushed by passers-by.
 Eye protection (goggles) worn when operating the machine, long hair should be tied back and
protected from entanglement. Loose clothing and jewellery should be tucked in / remove

Welding & Welding equipment HiGH

Hazards

 Compressed oxygen cylinders if damaged or involved in a fire can explode violently.  Oxygen leaks
make fires burn quicker and more violently.  Cylinders of acetylene gas can explode violently if involved
in a fire. Acetylene gas leaks can form an explosive mixture inside buildings.  Welding equipment can
present an electric shock hazard.  Sparks can cause burns to skin, eyes and clothes.  Hot metal
components can cause burns.  Chipping or cleaning welds can lead to eye injuries.  Ultraviolent and
infra red radiation can cause ‘arc eye’.  Welding can present a fire hazard.  Explosive vapours can form
inside containers that have contained flammable liquids.  Hazardous fumes can be produced.

Risk Control Measures

 Welding areas must be separated from other work areas by fixed or portable screens.  Welding areas
should be kept free of combustible materials and flammable liquids.  A good level of general ventilation
should be provided.  Welded materials should be put in a safe place to cool.  Appropriate goggles or
shields should be worn.  Appropriate personal protective equipment should be used. Fire resistant
aprons, gloves, face protection and sturdy protective footwear should be used.
3. Using power tools such as grinder, portable saw, pipe cutter, and pipe threading machine.

3a. Electric shock; electrocution. 3a. Inspect cord before use. Keep power cord away from work area.
Plug tools into GFCIprotected outlets. Do not use electric tools if work area is wet.

3b. Tripping over or cutting power cord. 3b. Keep power cord away from work area.

3c. Injury from flying bits of material. 3c. Wear safety glasses, and optionally a dust mask, gloves, long-
sleeve shirt and/or coveralls.

3d. Drill or saw catching; drill bit breaking; severe lacerations; dismemberment. 3d. Keep tools in good
condition. Inspect tools before use. Verify that guards work properly. Do not put hands near blades.
When using tools, make sure you have a good center of gravity and are properly balanced. Hold tools
securely with two hands to maintain control.

3e. Getting caught in pipe threading machine. 3e. Do not wear loose clothing, jewelry, or keys. Stay alert
while working with pipe threader.

3f. Back strain from using manual pipe threader. 3f. Position yourself properly when pushing the die
handle. PIPE FITTING HEAVY REFRIGERATION MECHANIC// SR. HEAVY REFRIGERATION MECHANIC

3g. Getting cut by metal chips. 3g. Properly dispose of rags used to clean pipe in order to prevent injury
to yourself or others from oil and metal chips.

5. Welding.

5a. Getting flashed. 5a. Wear welding mask. Prevent reflected arc rays by changing angle at which you
are working. If it is not possible to change your angle, put up a nonreflective board on the wall behind
you. All non-essential personnel should leave the area.

5b. Getting burned. 5b. Wear protective clothing: welding jacket, gloves, and welding mask.

5c. Hot metal bouncing up into face or eyes. 5c. Wear goggles or safety glasses under welding mask. 5d.
Fire hazard from flying sparks.

5d. Remove flammable materials from work area. Wear welding jacket. Have coworker fire watch with
an extinguisher.

5e. Inhalation of fumes. 5e. Use fans to ventilate area. Wear respirator.
5f. Electric shock; electrocution. 5f. Wear dry clothing. Make especially sure that gloves are dry. Keep
leads in good repair and out of standing water. Do not stand in standing water.

5g. Injury to others. 5g. Be aware of other workers or pedestrians in the area. Block welding area with a
screen.

Furnace

Hazard and Risk

The principal hazards are:

 burns from contact with hot surfaces or materials

 trauma injury by violent rupture of the reaction vessel
 toxic effects by exposure to fume or hazardous substances
 fire and explosion by the release and ignition of flammable or explosive substances
 electric shock by contact with the heating element or other live conductors.

Control Measures
The following control measures are recommended for use with furnaces.

 Use of tube furnace where the heating element is totally enclosed in a glass, ceramic or
insulating cover.
 Use of a separate variable auto-transformer (variac) to regulate the current, and hence the
temperature — the variac should have shrouded terminal connections, preventing contact
with any live conductor, and be wired so that in the off position both output conductors
are disconnected.
 Use of an independent temperature sensor which isolates the electrical supply if the
temperature rises above a preset value, if the furnace is to be left unattended.
 Use of a sealed tube vessel designed to withstand the maximum pressure likely to be
generated.
 Use of metal pipes to enclose any glass tubes in the tube furnace, or the entire assembly
placed behind a protective barricade inside a fume cupboard.
 Whether open or closed, tube reaction vessels should not be operated above the lower
flammable limit of any gas or vapour which is to be:
 introduced as a reactant
 introduced as an atmosphere gas
 formed as a reaction product.
 Tube furnace temperature should be allowed to rise slowly, or in steps, to avoid thermal
shock or stress to the reaction tube.
  Reaction and atmosphere gases passed through an open tube reaction vessel with gaseous
by-products should be safely vented to a fume cupboard or local exhaust ventilation
system.
 Before the reaction tube is removed, the furnace should be allowed to cool to room
temperature, and a positive pressure of inert atmosphere gas maintained in the reaction
vessel during cooling to prevent ingress of air.
 Prsonal protective equipment should be worn when handling the reaction tube and
includes:
 eye protection
 face protection
 heat-resistant gloves.

Forklift

 Overloading

 Unsafe stacking

 Speeding

 Raised forks

 Unauthorized operation of forklift

 Untrained forklift operators

 Lifting of persons on forks

 Pedestrians and forklifts moving in the same place

 Travelling on slope

 Obstruction in the path e.g. overhead, blind corners

 Poor ground conditions e.g. slippery, uneven, potholes

 Body/limbs caught in moving parts of the forklift

 Falling loads

 Poor condition tyres e.g. without thread markings

 Electric Shock (Battery operated forklift)