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Training Package Metal and Engineering (MEM05) HSC Requirements

and Advice
Title Apply safe welding practices
Unit code Competency field Band Unit weight HSC Indicative Hours

MEM05052A Fabrication A 4 10
Unit descriptor This unit covers identifying risks associated with welding operations and implementing hazard reduction practices.

Prerequisites None

Application of the This unit applies to gas and electric arc welding. It includes the identification of risks associated with welding all commonly used metals and implementation of
competency techniques used to reduce or eliminate welding hazards.

Related units –

Evidence Guide
The evidence guide specifies the evidence required to demonstrate achievement in the unit of competency as a whole. It must be read in conjunction with the unit descriptor,
performance criteria, range statement and the assessment guidelines for the Metal and Engineering Training Package.

Overview of assessment requirements Context of assessment Interdependent assessment Method of assessment

A person who demonstrates competency in This unit may be assessed on the job, off the This unit could be assessed in conjunction Assessors should gather a range of evidence
this unit must be able to apply safe welding job or a combination of both on and off the with any other units addressing the safety, that is valid, sufficient, current and authentic.
practices. job. Where assessment occurs off the job, that quality, communication, materials handling, Evidence can be gathered through a variety of
is the candidate is not in productive work, recording and reporting associated with ways including direct observation,
then an appropriate simulation must be used applying safe welding practices or other units supervisor’s reports, project work, samples
where the range of conditions reflects requiring the exercise of the skills and and questioning. Questioning techniques
realistic workplace situations. The knowledge covered by this unit. should not require language, literacy and
competencies covered by this unit would be numeracy skills beyond those required in this
demonstrated by an individual working alone unit of competency. The candidate must have
or as part of a team. The assessment access to all tools, equipment, materials and
environment should not disadvantage the documentation required. The candidate must
candidate. be permitted to refer to any relevant
workplace procedures, product and
manufacturing specifications, codes,
standards, manuals and reference materials.

Metal and Engineering Curriculum Framework June 2006 (updated unit codes Oct 2007) MEM05052A Apply safe welding practices 160
Evidence Guide cont/d HSC Requirements and Advice
Consistency of performance Required skills Required knowledge Key Terms and Concepts

Assessors must be satisfied that the candidate Look for evidence that confirms skills in: Look for evidence that confirms • characteristics and properties of common
can competently and consistently perform all • sourcing and interpreting safety-related knowledge of: metals and welding materials
elements of the unit as specified by the information and Material Safety Data • characteristics and properties of • correct manual handling techniques
criteria, including required knowledge, and be Sheets (MSDS) common metals and welding materials • effect of gas and electric arc welding on metals
capable of applying the competency in new • planning and sequencing operations • effect of gas and electrical welding • effect of treatments on metals
and different situations and contexts. • identifying workplace risks and operations on metals • electric arc welding processes/operations
nonconformances • hazards and control measures • exposure levels
• reporting workplace risks and associated with gas and electrical • factors associated with increased risk
nonconformances welding, including housekeeping • gas welding processes/operations
• checking and clarifying task-related • welding safety practices and procedures • gases in welding
information. • effect of various treatments on a range • hazard identification
of commonly used metals • Material Safety Data Sheets (MSDS)
• use and application of personal • occupational disease and injury
protective equipment. • occupational health and safety (OHS)
• OHS legislation
• participation
• personal protective equipment (PPE)
• pollutants
• recording and reporting
• risk control
• risk management
• safe work practices and procedures
• safe work practices for using welding tools,
equipment and processes
• sources of OHS information
• work-related safety information
• work sequencing
• workplace documentation
• workplace safety non-compliances.

Metal and Engineering Curriculum Framework June 2006 (updated unit codes Oct 2007) MEM05052A Apply safe welding practices 161
Elements Performance criteria Range Statement HSC Requirements and Advice
1 Access and interpret OH&S 1.1 OH&S information is obtained and The range statement provides information Learning experiences for the HSC must address:
information interpreted. about the context in which the unit of
An awareness of sources of information regarding
competency is carried out. The variables [in
bold] and scope [dot points] cater for different occupational health and safety (OHS) in the
work requirements, work practices and workplace including:·
knowledge between States, Territories and the • organisation/company policies and procedures
Commonwealth, and between organisations - project/site safety plan
and workplaces. The range statement relates to - emergency plan
the unit as a whole and provides a focus for - Australian Standards
assessment. Text in italics in the performance - training manuals
- operator’s manuals
criteria is explained here.
• WorkCover NSW publications/safety alerts
The following variables may be present and • National Occupational Health and Safety
may include, but are not limited to, the Commission (NOHSC) guidelines
examples listed under the scope. All work is • legislation/regulations/codes of practice
undertaken to relevant legislative • standard operating procedures (SOP)
requirements, where applicable. • standard operation sheets
• Material Safety Data Sheets (MSDS)
OH&S information • manufacturer’s specifications.
• National Occupational Health and Safety
Commission guidelines
• organisational OH&S practices and
procedures manuals
• Australian/New Zealand and ISO standards
• company risk management policy
• codes of practice
• Australian dangerous goods legislation
• trade practices
• occupational health and safety reporting
requirements
• weld procedures.

1.2 Relevant OH&S legislation is identified. Learning experiences for the HSC must address:
A basic awareness of the difference between:
• legislation
• regulation
• codes of practice.

A basic understanding of OHS legislation regulations


and codes of practice including:
• Occupational Health and Safety Act 2000 (NSW)
• Occupational Health and Safety Regulations 2001

Metal and Engineering Curriculum Framework June 2006 (updated unit codes Oct 2007) MEM05052A Apply safe welding practices 162
Elements Performance criteria Range Statement HSC Requirements and Advice
(NSW)
• Codes of practice (WorkCover NSW):
- OHS Consultation
- Risk Assessment.

1.3 Work related safety information is Work related safety information


obtained and interpreted. • standard operating procedures
• material safety data sheets (MSDS)
• job sheets
• emergency procedures
• safety standards and procedures.

2 Identify risks associated with 2.1 Pollutants formed by welding processes Pollutants Learning experiences for the HSC must address:
welding are identified. • nitrogen oxides
• ozone Identification of potential hazards to:
• metal fumes etc. • self
• lead oxide • colleagues
• silicon oxide • visitors
• calcium fluoride • general public.
• calcium oxide
• magnesium oxide A basic understanding of risk management:
• identify hazards
• sodium oxide
• potassium oxides • assess associated risks
• carbon dioxide • use appropriate control measures to eliminate/
• organics minimise risks
• iron • monitor and review the control measures.
• manganese
• calcium carbonate An awareness of pollutants associated with gas and
• zirconium oxide electric arc welding.
• titanium oxide
• hexavalent chromium.

2.2 Occupational diseases and injuries Occupational diseases and injuries Learning experiences for the HSC must address:
which may be associated with welding • eye injuries
are identified. • skin damage A range of occupational diseases and injuries that can
• respiratory irritations result from gas and electric arc welding.
• chronic effects
• allergies.

2.3 Factors associated with increased risk Factors Learning experiences for the HSC must address:
are identified. • gas leakage from cylinders
• type of consumable and metals used A range of factors that can increase risks associated
with gas and electric arc welding.

Metal and Engineering Curriculum Framework June 2006 (updated unit codes Oct 2007) MEM05052A Apply safe welding practices 163
Elements Performance criteria Range Statement HSC Requirements and Advice
• type of welding processes
• type of electrodes
• welding current
• voltage and amperage
• ventilation
• contamination
• interaction of chemicals
• exposure levels
• flammability.

2.4 Exposure levels for pollutants are Exposure levels Learning experiences for the HSC must address:
identified. • time weighted average
• Short Term Exposure Limit (STEL) A basic understanding of the following concepts:
• time weighted average
• Maximum Allowable Concentration (MAC)
or Threshold Limit Value – Ceiling • Short Term Exposure Limit (STEL)
(TLV-C) • Maximum Allowable Concentration (MAC) or
• skin notation. Threshold Limit Value - Ceiling (TLV-C)
• skin notation.

An awareness of:
• allowable exposure levels for a range of pollutants
• typical workplace settings that ensure exposure
levels close to a safe upper limit
• machines/chemical processes used to measure
exposure levels.

2.5 Risks and potential health effects Specific metals Learning experiences for the HSC must address:
associated with specific metals are • aluminium
identified. • antimony Knowledge of the characteristics and properties of a
• arsenic range of common metals and welding materials.
• beryllium
• boron Knowledge of the effect of:
• cadmium • gas and electric arc welding operations on a range
• chromium of commonly-used metals
• copper • various treatments on a range of commonly-used
• cobalt metals.
• iron
• lead
• lithium
• magnesium
• manganese
• mercury
• molybdenum

Metal and Engineering Curriculum Framework June 2006 (updated unit codes Oct 2007) MEM05052A Apply safe welding practices 164
Elements Performance criteria Range Statement HSC Requirements and Advice
• nickel
• platinum
• selenium
• silver
• thorium
• tin
• titanium
• tungsten
• vanadium
• zinc
• zirconium.

2.6 Risks and potential health effects Gases


associated with gases in welding are • acetylene
identified. • argon
• carbon dioxide
• carbon monoxide
• helium
• nitrogen oxides
• ozone
• phosgene
• phosphine
• stibine.

2.7 Other hazards of welding are identified. Other hazards


• fluxes
• electro-magnetic radiation
• electric shock
• sparks
• spatter
• contaminated and coated metals
• gas cylinder and electrical hazards
• confined spaces
• noise
• chemical exposure
• solvents
• musculoskeletal, back and overuse injuries
• vibration
• dusts
• heat stress
• ultraviolet radiation
• airborne pollutants
• flammable gases

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Elements Performance criteria Range Statement HSC Requirements and Advice
• infrared radiation
• thermal damage.

3 Reduce risks associated with 3.1 Manual handling techniques are used. Manual handling techniques Learning experiences for the HSC must address:
welding • housekeeping practices
A basic knowledge of National Occupational Heath
• lifting weight limits
• appropriate storage and Safety Commission (NOHSC) guidelines for
• use of lifting devices manual handling.
• appropriate training
• hazardous materials storage standards and An awareness of legal requirements for weight limits.
procedures.
Awareness of correct manual handling techniques
when:
• moving
• lifting/carrying
• using hand tools
• loading/unloading
• working at heights
• bending and twisting
• using mechanical aids
• undertaking repetitious tasks.

3.2 Personal protective equipment is used Personal protective equipment Learning experiences for the HSC must address:
correctly. • respirators
• ear muffs Use and application of a range of personal protective
• protective clothing equipment (PPE) including:
• gloves • footwear
• boots • head protection
• helmets • gloves
• eye protection • protective clothing
• respirator
• face shields.
• face mask/shield
• hearing protection
• eye protection.
Selection of PPE:
• correct for the task
• manufacturer’s specifications for use
• correct fitting
• serviceability.

Maintenance of PPE according to manufacturer’s


instructions and enterprise SOP:
• cleaning and decontamination·
• correct storage

Metal and Engineering Curriculum Framework June 2006 (updated unit codes Oct 2007) MEM05052A Apply safe welding practices 166
Elements Performance criteria Range Statement HSC Requirements and Advice
• regular checks for damage
• repair/replacement of worn, malfunctioning or
damaged equipment/parts
• disposal of single-use equipment.

Importance of correct fitting PPE.

3.3 Procedures to control hazards are Procedures to control hazards Learning experiences for the HSC must address:
implemented. • substituting hazardous materials with safer
materials A basic awareness of the hierarchy of risk control
• changing workplace design to eliminate measures:
hazards • Level 1 – eliminate the risk (such as discontinue the
• modifying work practices to reduce activity or not use the equipment)
• Level 2 – minimise the risk by:
exposure
• using personal protective equipment - substituting the system of work/equipment (with
• using adequate and appropriate ventilation. something safer)
- modifying the system of work/equipment (to
make it safer)
- isolating the hazard (such as introducing a
restrictive work area)
- introducing engineering control (such as
guarding, fencing or safety screens)
• Level 3 – other controls:
- adopt administrative controls and safe work
practices
- use PPE.

3.4 Workplace safety procedures are Workplace safety measures Learning experiences for the HSC must address:
implemented. • shielding requirements
• ventilation Safe work practices and procedures.
• general and diluted
• local exhaustion Hazard identification and risk control.

• use of personal protective equipment Housekeeping/clean-up procedures with due


• checking equipment condition consideration to OHS and the environment.
• equipment maintenance
• correct operation of equipment Safe work practices for using welding tools,
• correct voltage and electrical connections equipment and processes including:
• good posture • following SOP and manufacturer’s specification
• fire safety, plant and equipment isolation before, during and after use
• communications with appropriate • risk management (identifying hazards and
personnel. implementing control measures)
• correct manual handling
• safe handling, application and storage of hazardous

Metal and Engineering Curriculum Framework June 2006 (updated unit codes Oct 2007) MEM05052A Apply safe welding practices 167
Elements Performance criteria Range Statement HSC Requirements and Advice
substances
• appropriate use of PPE
• regular servicing and maintenance of tools and
equipment
• selection of appropriate tool for use
• working with electricity in a safe manner
• adequate ventilation
• attaching appropriate safety guards where required
• awareness of OHS issues in relation to welding.

An awareness of information provided in MSDS:


• manufacturer’s/supplier’s details
• physical description and properties
• identification of substance
• use
• ingredients
• health hazard information
• first aid
• precautions for use
• safe handling information
• control point.

How and where to obtain required MSDS.

Work sequencing including:


• receiving instruction
• organising for the task:
- selection of tools and equipment
- locate materials and/or parts
- PPE
• carry out the task:
- in a logical order
- within completion time frame
- according to quality measures
• clean-up after task completion.

3.5 Workplace safety non-compliances are Learning experiences for the HSC must address:
reported in accordance with workplace
procedures. The concept of ‘participation’ as it related to
workplace safety and employee rights and
responsibilities.

How and when to report.

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Elements Performance criteria Range Statement HSC Requirements and Advice
A basic awareness of monitoring and reporting for
OHS including:
• formal/informal
• verbal
• written
- safety inspection reports
- checklists
- accident reports
- WorkCover NSW notification
- registers/logs/files.

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