WORKSHOP FABRICATION Networks Safeguard Safe Work Method Statement

SAFE WORK METHOD STATEMENT – WORKSHOP FABRICATION

HSE NET NAT SWMS APAND00033

APT AM Holdings Pty. Ltd.

Principal Contractor (PC)
[ABN] 95124754383
APA Group
Level 19, HSBC Building Subcontractor
580 George Street
Sydney NSW 2000
State Representative :

Person responsible for
reviewing & approving the
SWMS
John Ferguson
Sign: Refer to Approval Sign off Sheet APADN00020
Executive Manager, Networks Signature and Date
Date: 26/06/2013
Phone 02 9693 0057

Date SWMS provided to PC 04/03/2013 Provided to: Robin Gray

Work Description
Work Location /Address
The following personnel who
have consulted and assisted in
the development of this SWMS
[Project ID, title or equivalent]
SAFE WORK METHOD STATEMENT
Project Reference
Various welding and fabrication works completed in
the workshop
Person Responsible for ensuring
Workshop Supervisor Fabrication Services
compliance with SWMS on site
Heath Lynch, Daniel Reid Review date for this SWMS March 2014

PERSONNEL SITE CONTENT

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 WORKSHOP FABRICATION Networks Safeguard Safe Work Method Statement
 AS1796 Qualified welding supervisor (as required) NA
 Supervisor Fabrication Services (as required) Permit to Work &
Required Supervision other Approval
Typically the works undertaken within the workshop do Requirements
not require continuous supervision.

 Trade Certificates  Grinders / Buffer

 Weld Certificates  Saws
 Weld Procedure Qualifications  Drill press
 Welding Supervisor (AS1796)  Slings
 Experience in welding processes  Crane
 Welding Rig
 Lathe
 Milling machine
 Oxy / Acetylene Trolley
 Hand Tools powered and unpowered
 LPG / Oxyacetylene Gas Torch
 Electrode hot box
 Pipe stands
Plant, Equipment,
Required Qualifications  Jacks
Materials
 Bonding straps / Earth stakes
 Neon tester (Volt finger)
 Lighting
 Gas detector
 DN20 – DN300 carbon steel pipe
 DN8 – DN300 carbon steel fittings e.g. tees, elbows,
reducers etc.
 Flat bar – steel
 Plate – steel
 RHS – Steel
 SHS - Steel
 Sheet metal

Required Training  APA induction Card or Short term induction Hazardous  Refer to SDS Register in workshop

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 WORKSHOP FABRICATION Networks Safeguard Safe Work Method Statement
 Construction Industry General Induction Substances
 Workplace Specific Induction (if required)
 Induction in to this SWMS

 Induction to APA Pre Start HSE Check/Plan

 Overhead crane training

 Competency training for use of machine shop

equipment

 High Visibility Clothing – Day and Night  Fire extinguishers

MANDATORY  First aid kits
 Safety Gloves (as required)  Site evacuation plan
 Safety Glasses Clear and Sunglasses MANDATORY
 Hearing Protection – Earmuffs / Earplugs (as
required)
Emergency
Personal Protective  Safety Boots - Steel Cap MANDATORY Procedures and
Equipment (PPE)
 Protective Clothing – Must meet and be used as per Equipment
APA Operations Field Book Procedure 5206
 Safety Helmet As Required
 Sun Lotion (as required)
 Sun Hat (as required)
 Welding shields (as required)

REFERENCES ASSOCIATED DOCUMENTS

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 WORKSHOP FABRICATION Networks Safeguard Safe Work Method Statement
 Work Health & Safety Act 2012  APA JHEA
 Work Health & Safety Regulations 2012  APA traffic management check/plan Book
 Work Health & Safety Plant Code of Practice  APA Operations Field Book
 Work Health & Safety Risk Management Code of Practice  Safeguard
 Work Health & Safety Noise Code of Practice  Qualified APA welding procedures
 AS 1742.3:2009
 AS2885.2:2007
 AS3992:1998
Step What are the tasks Hazards/risks Raw Risk Controls to be implemented to reduce Residual Risk Person responsible
No. involved? What can happen and how can it risks Who will make sure
in order of job sequence happen? What will be done to ensure zero harm? it happens?
Break the job down into Specify the potential hazards Assess the raw Describe the measures to be Assess the Specify Person(s)
steps. Each step should associated with each step and risks risk without implemented to eliminate or control the residual risk Responsible
accomplish some major to health, safety and the controls risks. Describe how these measures are with controls
task and be in a logical environment. Examine each to find to be implemented, monitored and
sequence possibilities that could lead to an reviewed.
incident.
 Pinch injury caused by loading  Plant risk assessments
material onto the forklift and/or  Review PPE requirements
pallets 
 Crush injury caused by  Equipment maintenance
 Welder
unrestrained materials falling  Qualified staff
from forklift  Fitter
 APA Group JHEA to make aware all
 Crush injury caused by forklift  Machinist
personnel working in area
falling onto personnel due to  Boiler Maker
 Task Rotation
Operation of electric overloading and/or incorrectly  Physical Barriers / Exclusion Zones  Supervisor
1. High Moderate
forklift positioning the load on the (where applicable) Fabrication
forklift  Safety Signage Services
 Crush injury caused by forklift  Housekeeping  Pressure
running over personnel due to  Inspect forklift before use to Controller
inappropriate operation ensure no damage and functional
 Hand/foot crush injury caused  Lifting aids / dual lift – Manual
by lowering the forklift onto a Handling training
fixed surface such as the tray of
 Assess load shape, size and weight
a truck
of object to be moved and ensure
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 Impact injury caused by
material/forklift hitting
personnel due to reduced vision
and awareness. All body parts
may be exposed to this injury
due to different operating
heights
 Slips, Trips, Falls resulting in
injury. This may also result from
working on uneven surfaces
 Strains and fatigue caused by
continuous hand position on
forklift handle
 Personal injury from cutting
equipment
 Noise exposure resulting in
hearing damage
 Sparks resulting in fire hazard
 Potential fall / crush from
material rolling or falling
 Airborne debris from cutting
process causing potential eye
injury
 Electric shock from power tools
2. Cutting material  Fire / Explosion
 Hot / molten metal resulting in
burns
 Fume inhalation causing
respiratory complications
 Heat exhaustion / stroke
 Slips, Trips, Falls resulting in
injury
 Pipe setup causing ergonomic
issues
 Manual tasks resulting in
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WORKSHOP FABRICATION Networks Safeguard Safe Work Method Statement
forklift is applicable
 Correct restraint of load on forklift
 .
 Review PPE requirements
 Inspect cutting equipment
before use to ensure no damage
and functional
 Job setup to separate heating
zone from gas supply hoses to
avoid hose damage  Welder
 Machine Guarding in place  Fitter
 Electrical Test and Tag  Machinist
 Equipment maintenance  Boiler Maker
 Qualified staff
High Moderate  Supervisor
 Safety Screens
Fabrication
 APA Group JHEA
Services
 Extraction fans
 Cold water available  Pressure
Controller
 Task Rotation
 Physical Barriers / Exclusion
Zones
 Safety Signage
 Housekeeping
 Lifting aids / dual lift – Manual
Handling training (as required)
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 WORKSHOP FABRICATION Networks Safeguard Safe Work Method Statement
muscular pain and injury  Chocks to prevent material
 Impact injury caused by cutting rolling / falling.
equipment catching on pipe  Residual Current Device (RCD)
work not sufficiently secured  MSDS available and current
 Personal injury from equipment
 Noise exposure resulting in  Plant risk assessments
hearing damage  Review PPE requirements
 Sparks resulting in fire hazard  Inspect drilling equipment
 Potential fall / crush from before use to ensure no damage
material rolling or falling and functional
 Airborne debris from machine  Job setup to separate drilling
process causing potential eye zone from electrical supply
injury cables to avoid cable damage
 No loose clothing / jewellery  Welder
 Electric shock from power tools  Fitter
 Burns from hot material  Electrical Test and Tag
 Equipment maintenance  Machinist
 Fume inhalation causing  Boiler Maker
respiratory complications  Qualified staff
3. Drilling
 Hot Swarf / Sharp Swarf
Moderate  Non-lockable hand drills to be Minor  Supervisor
used Fabrication
 Slips, Trips, Falls resulting in
injury  APA Group JHEA Services
 Injury caused by pipe setup and  Cold water available  Pressure
ergonomics  Task Rotation Controller
 Manual tasks resulting muscular  Safety Signage
pain and injury  Housekeeping
 Entanglement in drilling  Lifting aids / dual lift – Manual
operation from loose items Handling training
 Impact injury caused by drill  Correct restraint of work piece
catching on pipe work not  Ensure chuck key is removed
sufficiently secured before operation
 Strains and sprains  MSDS available and current
 Personal injury from grinder  Plant risk assessments
equipment  Welder
Grinding / Buffing / Lathe /  Do Not use handheld 9”
4.  Noise exposure resulting in High Moderate  Fitter
Other Machining Grinders
hearing damage  Machinist
 Inspect cutting equipment
 Sparks resulting in fire hazard  Boiler Maker
before use to ensure no damage
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 Potential fall / crush from
material rolling or falling
 Airborne debris from
grinding/buffing process causing
potential eye injury
 Electric shock from power tools
 Burns from hot material
 Fume inhalation causing
respiratory complications
 Heat exhaustion / stroke
 Slips, Trips, Falls resulting in
injury
 Injury caused by pipe setup and
ergonomics
 Manual tasks resulting in
muscular pain and injury
 Impact injury caused by grinder
/ buff catching on pipe work not
sufficiently secured
 Strains and sprains
 Fire / Explosion
 Burns from heating torch
 Fume inhalation causing
respiratory complications
 Gas leak
 Heat stroke / exhaustion
Heating (heating torch –
5.  Noise exposure resulting in
LPG, Oxyacetylene)
hearing damage
 Potential fall / crush from
material rolling or falling
 Slips, Trips, Falls resulting in
injury
 Injury caused by pipe setup and
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WORKSHOP FABRICATION Networks Safeguard Safe Work Method Statement
and functional  Supervisor
 Review PPE requirements Fabrication
 Job setup to separate grinding Services
zone from electrical supply
 Pressure
cables (to avoid cable damage)
Controller
 Machine Guarding in place
 Electrical Test and Tag
 Equipment maintenance
 Qualified staff
 Safety Screens
 APA Group JHEA
 Cold water available
 Task Rotation
 Physical Barriers / Exclusion
Zones
 Safety Signage
 Housekeeping
 Lifting aids / dual lift – Manual
Handling training
 Chocks to prevent material
rolling / falling.
 Correct restraint of work piece
 Review PPE requirements
 Inspect heating equipment
before use to ensure no  Welder
damage and functional  Fitter
 Job setup to separate heating  Machinist
zone from gas supply hoses (to  Boiler Maker
High avoid gas hose damage) Moderate  Supervisor
 Soap test of all pressure Fabrication
connections Services
 Qualified staff  Pressure
 Flash-back arresters Controller
 Equipment maintenance
 MSDS available and current
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(Manual Metal Arc
Welding, Gas Tungsten Arc
Welding, Gas Metal Arc
6.
Welding) Engine driven
(mobile) or electric driven
(static).
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WORKSHOP FABRICATION Networks Safeguard Safe Work Method Statement
ergonomics  Physical separation from other
 Manual tasks resulting in flammable material
muscular pain and injury  Braided hose for LPG torch
 Uncontrolled pressure release of  APA Group JHEA
gas cylinders resulting in  Cold water available
personnel injury  Task Rotation
 Physical Barriers / Exclusion
Zones
 Safety Signage
 Housekeeping
 Chocks to prevent material
rolling / falling.
 Review PPE requirements
 Welding flash (eye burns)
 Inspect welding equipment
 Noise exposure resulting in
before use to ensure no damage
hearing damage
and functional
 Sparks resulting in fire hazard
 Equipment maintenance
 Potential fall / crush from
 Qualified staff
material rolling or falling
 APA Group JHEA  Welder
 Electrocution from welding  Fitter
 Anti-flash glasses for welding Minor
current High (Welders
assistant and supervisor (Welders  Machinist
 Fire resulting in potential burns flash)
 Cold water available flash)  Boiler Maker
 Hot metal resulting in burns
 Task Rotation  Supervisor
 Fume inhalation
High  Physical Barriers / Exclusion Fabrication
 Molten Metal / weld material (Electrocution)
Moderate
Services
Zones
 Heat exhaustion / stroke (Electrocution)
 Safety Signage  Pressure
 Slips, Trips, Falls
 Housekeeping Controller
 Pipe setup causing ergonomic
 Lifting aids / dual lift – Manual
issues
Handling training
 Manual tasks resulting in
 Chocks to prevent material
muscular pain and injury
rolling / falling.
 MSDS available and current
 Voltage Reduction Devices
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 WORKSHOP FABRICATION Networks Safeguard Safe Work Method Statement
(VRDs)
 Residual Current Device (RCD)
 Air Fed Respirators (P3)
(Welding)
 Galvanising to be removed
before welding
 Welding shields
 Welding screens
STOP all work activities

 Ensure task and equipment is made  Welder

safe  Fitter
 Hold a tool box meeting and record  Machinist
and adjust
Deviation from this Safe  Boiler Maker
Work Method  Miscommunication by all parties  Complete JHEA for variations from
7. High Moderate  Supervisor
Statement onsite. work method – obtain approval
from site representative. Fabrication
 Authorised by competent Services
person, supervisor or HSE Advisor  Pressure
 Sign off on changes prior to the Controller
recommencement of work

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 WORKSHOP FABRICATION Networks Safeguard Safe Work Method Statement
Declaration by contractors and workers
- I have been given the opportunity to comment on the content of this SWMS.
- I have read and understand how I am to carry out the activities listed in this SWMS.
- I have been supplied with the personal protective equipment identified on this SWMS and I have been given training in the safe use of this equipment.
- I have read and understand the requirements set out in the material safety data sheets for the hazardous substances identified in this SWMS

Consultation & Review Sign Off Analysis of Training / Skills or Competencies Required

General Industry

Project Specific

[ List others]
Training / Skill / Competency Required to Complete the Work Safely

Induction

Induction
% of personnel required to hold
A = All employees are required to hold. A A
Number of personnel required to hold
Training / Skill / Competency held by employee – tick () – evidence must
Name Position Signature Date
be available

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 WORKSHOP FABRICATION Networks Safeguard Safe Work Method Statement

Risk Assessment
CONSEQUENCE
RISK RANKING ACTION REQUIRED HSE First aid treatment External medical Injury or illness requiring Permanent partial Fatality OR Multiple fatalities
only with the ability treatment but hospitalisation and disability permanent total
Negligible Work can proceed once risk controls
identified and implemented
to return to work excluding resulting in the inability disability
immediately hospitalisation with to return to work the
Work can proceed once risk controls the ability to return next day (LTI
Minor
identified and implemented
to work the next
Moderate Work can proceed once supervisor work day
has confirmed process has been
adequately followed and risk controls
identified and implemented

High Reduce risk to at least moderate or to

ALARP through additional controls.
Activity must not commence
without Management approval

Extreme Activity must not commence.

Reduce risk to at least moderate or to
ALARP through additional controls.
Environment Limited impairment to
minimal area of low
significance
Short-term (<12 months) Prolonged (<5 years)
temporary impairment reversible impairment to the
to the biological or biological or physical
physical environment of environment of a localised
a very localised area area (<1ha) which is easily
(<0.1ha) rectified and which does not
affect ecosystem function
Uncontrolled off-site An uncontrolled off-site Uncontained, long-term
release or event. release or event in wide serious environmental
Reversible prolonged area resulting in degradation OR
impairment to the reversible long-term permanent impairment
environment but which environmental to ecosystem function or
does not affect impairment of habitat
ecosystem function ecosystem function

Probability Historical Descriptor LEVEL 1 LEVEL 2 LEVEL 3 LEVEL 4 LEVEL 5 LEVEL 6

Is expected to occur
At least once per
in most Frequent Minor Moderate High Extreme Extreme Extreme
year
circumstances
At least once every Expected to occur
Likely Minor Moderate High High Extreme Extreme
1 to 5 years infrequently
At least once every May occur
Occasional Minor Minor Moderate High High Extreme
5 to 10 years occasionally
At least once every Might occur at some
Possible Negligible Minor Moderate High High High
10 to 50 years time
Could occur at some
At least once every
LIKELIHOOD

Minor
time but not Unlikely Negligible Moderate Moderate High High
50 to 100 years
considered likely
Conceivable but only
Less than once
in exceptional Improbable Negligible Negligible Minor Moderate Moderate High
every 100 years
circumstances

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