TIG WELDER

SCOPE This document is to be completed for staff and student use of machinery, plant & equipment as a part of a school curriculum activity or program.

Refer to the ITD Guidelines for further staff advice on the risk management process for practical ITD curriculum activities in schools.

Plant / Equipment Description:

Teachers / Leaders:

Room Locations:

Assessment Date: Review Date:

N.B. This assessment can remain active for up to 5 years. However, an annual monitoring & review process should be undertaken and recorded – refer to the last page of this document.

Below are the details of the manufacturing or production processes attributed to this item of equipment categorised by their assessed inherent risk levels (refer to the Equipment / Process Risk Matrix). The actions required for approval for each level of inherent risk are mandatory.

Inherent Risk Level Details of Processes Action Required / Approval CAUTION – Intense electromagnetic interference generated from high voltage Arc Welding equipment has the potential to cause cardiac pacemakers to operate incorrectly. If concerned seek medical advice before operating – remain at least 2 meters from the power unit and 1 meter from the welding arc.

 When welding (fusing) various metals, even two dissimilar metals. The TIG welding process is very handy for making the more difficult welds including tight s-curves or welds on rounded pipe work and flanging.  A Plant Risk Assessment is  When the TIG welder is used correctly and required to be completed. carefully for the purposes for which it was designed.  Principal or Classified Officer (i.e. DP, HOD, HOC, HOSES) High   Metals that can commonly be welded using approval prior to conducting this this process include: Mild steel, aluminium, activity is required. titanium, copper and stainless steel.  Obtaining parental permission is  When all appropriate welding PPE is recommended. available and are worn by all participants.  When all resulting UV radiation is shielded.  When welding bays are designed to allow for appropriate ITD teacher supervision.

DETE - Organisational Health Unit Issued: November, 2013. V3 Page 1 of 8 Uncontrolled when printed Minimum Standards

Minimum Qualifications and Experience Listed below are the general “Minimum” recommendations for the management of this Plant / Equipment.  Indicate the minimum management controls.

Registered teachers with experience, ability and competency in the safe use of this plant / equipment (indicate one or more of the following):

Specific knowledge of the safe and correct use of this plant / equipment;

Experience (i.e. previous involvement and familiarity) in the safe use of this plant / equipment;

Demonstrated expertise, ability and competency with this plant / equipment;

Documented qualifications relating to the use of this plant / equipment ( e.g. in a staff profile ) OR An adult staff member or leader, other than a registered teacher, with :

Expertise in the safe and correct use of this plant / equipment; Documented qualifications that demonstrate experience, ability and competency in the safe use of this plant / equipment.

Will any ITD staff require initial and/or ongoing training for the safe use of this plant / equipment ? If yes, give details:

Will students be operating this plant / equipment ?

If yes, state how student use of this plant / equipment will be managed ( e.g. Workshop Safety Induction ) Give details:

Further information if required:

Minimum Control Requirements

Supporting documentation available in the school on this plant / equipment includes: Operators Manual Safe Operating Procedures – (SOP) Equipment Maintenance Records – (EMR)

A process for recording student safety induction ( link to example )

A process for recording staff training & experience – e.g. ITD Staff Profile ( link to example )

All guards are in place & in good working order for this plant / equipment

Safe Working Zones are defined for this plant / equipment (e.g. yellow lines and / or appropriate signage) Suitable personal protective equipment (PPE) is available to be used by all operators This plant / equipment complies with relevant safety standards

Further information if required:

DETE - Organisational Health Unit Issued: November, 2013. V3 Page 2 of 8 Uncontrolled when printed Hazards and Control Measures

Listed below are indicative hazards/risks and suggested control measures. They are by no means exhaustive lists. Add details of any other hazards/risks or additional controls you intend to implement.  Indicate the Control Measures adopted. Detail their implementation and any additional controls required.

Details of how this will Hazards/Risks Hierarchy of Recommended Yes No be implemented Control Measures ( and any additional controls )

Exposure to Rotating 1. Where possible, potentially hazardous or Moving Parts: portable welding equipment, including all TIG welders, are substituted or replaced  Entanglement & with less hazardous alternatives. Entrapment 2. All necessary guards & safety devices are Could hair, clothing, ties, in place protecting workers from hazards jewellery or other materials including IR & UV radiation, electrical become entangled with components or cabling & dangerously hot moving parts of plant or molten metal. materials in motion? 3. Staff & student training is provided to  Crushing & minimise exposure to these hazards & Pinching risks. Could anyone be crushed or pinched due to falling, 4. Safe operating procedures (SOP’s) are uncontrolled or unexpected available & clearly displayed. movement of plant or its load tipping or rolling over, or 5. Warning “Danger” tags (or similar) are contact with moving parts affixed to all welding equipment under during testing, inspection or repair or maintenance preventing workers maintenance? from using the equipment.

 Striking 6. “Safe Working Zones” are clearly defined. Could anyone be struck by Where practical, all TIG welding activates moving objects such as the are isolated away from others. work piece being ejected, or by the unexpected or 7. Operators are required to remove all uncontrolled movement of the jewellery, tuck in loose clothing & tie back plant or work piece? long hair.

 Cutting, Stabbing 8. All approved personal protective & Puncturing equipment (PPE) is used where required. Can anyone be cut, stabbed or punctured by coming into 9. Specifically, approved protective welding contact with moving plant or helmets & goggles, leather aprons, jackets parts, or objects such as a and work boots are worn by all workers protruding welding work piece when operating any welding plant & or waste materials? equipment.

Slips, Trips, Falls & 1. Slip resistant flooring is encouraged. Abrasions: Regular checks are made for unsafe wear & damage. Inspections are made for any power leads and gas lines. etc. Can anyone using the plant or in the vicinity of the plant, slip, 2. Procedures are in place for the disposal of trip or fall due to the working all waste materials around all TIG welding environment or other factors? activities.. e.g. Poor housekeeping, dust on floors, slippery or uneven 3. Staff training is provided to minimise work surfaces, power cables exposure to these hazards. across work areas causing injuries & abrasions?

DETE - Organisational Health Unit Issued: November, 2013. V3 Page 3 of 8 Uncontrolled when printed Details of how this will Hazards/Risks Hierarchy of Recommended Yes No be implemented Control Measures ( and any additional controls )

Environmental: 1. All portable welding equipment is regularly maintained to help minimise the risk of  Noise exposures to these hazards. Is it likely that the normal 2. All portable welding equipment operation of this plant will maintenance is documented. produce excessive noise 3. Exposure to noisy ITD workshop levels? environments is monitored & evaluated  Dust, Fumes & regularly for all workers. Vapours 4. Engineering controls (or physical changes) Is it likely there will be airborne such as mandatory machinery guarding or dust particles, toxic fumes or any protective safety screens & enclosures volatile vapours produced & are in place in all workspaces & all in good therefore be present in the working condition. workspace? 5. Staff & student training is provided to  Vibration minimise exposure to these hazards. Is the normal operation of this 6. All ducted welding fume & dust extraction plant likely to create severe or systems are fully maintained, cleaned & excess vibration that could be emptied, connected & operational. transferable to the operator? 7. Good lighting is provided to all workspaces  Lighting and this is maintained on a regular basis. Is there insufficient lighting to Fluorescent tubes are checked & replaced operate this plant in a safe as required. manner? Is there a possible strobe lighting effect caused 8. All approved personal protective by faulty fluorescent tubes in equipment (PPE) is used where required. the workspace?  Water & Moisture Is there a danger of surface water on the floor in the workspace?

Electrical: 1. All portable electric welders have a wall mounted isolation switch that disconnects Can the operator be injured by all electrical power. electrical shock due to “Lock Out” or warning “Danger” tags are working near or contacting 2. with damaged or poorly affixed to all electrical welding equipment maintained live electrical under repair or maintenance preventing conductors such as power workers from using the equipment. outlets, extension leads, 3. Visually checks are made of all portable safety switches, starters & electrical welding equipment, their isolators or casual water on electrical switches, plugs & power leads, the floor near plant & etc. machinery? 4. Electrical safety inspections, testing & tagging, etc. are completed regularly as per guidelines for all portable electrical welding equipment.

5. Electrical maintenance on all portable power tools is documented.

DETE - Organisational Health Unit Issued: November, 2013. V3 Page 4 of 8 Uncontrolled when printed Details of how this will Hazards/Risks Hierarchy of Recommended Yes No be implemented Control Measures ( and any additional controls )

Exposure: 1. Portable welding equipment is regularly maintained to help minimise the risk of exposures to these hazards.  Heat, Burns & Scalds Could the plant operator be 2. Plant & machines likely to generate exposed to heating elements, excessive heat or sparks are isolated, exposed flame, flashback, ventilated & monitored closely. molten metals or hot fluids 3. All portable welding equipment likely to cause scalding or maintenance is documented in a register. burning? Humid & hot work environments are often 4. Welding bays are designed to allow for uncomfortable resulting in appropriate teacher supervision. stress & low productivity. ® 5. Spectra PVC welding curtains (or similar)  Friction are provided around all electrical welding bays to help prevent others looking at an Is the plant likely to generate electric arc or "welder's flash". heat by friction? Could the 6. Any hazardous waste materials or toxic plant operator accidentally dusts & gases resulting from this welding come into contact with moving process are monitored. materials or machinery components resulting in 7. Staff & student training is provided to friction burns to the skin, minimise exposure to these hazards. particularly hands? 8. “Safe Working Zones” are clearly defined.  Radiation Where practical, all welding activates are isolated away from others. Could workers be exposed to UV & IR radiation? Working 9. All approved personal protective with an electric arc welder equipment (PPE) is used where required. exposes workers to many 10. Specifically, approved protective gloves dangers, including burns. An are issued & worn in circumstances where electric arc will generate UV & plant operators hands could be exposed to IR radiation causing serve extreme heat, friction, abrasion or chemical burning & discomfort to burns, etc. unprotected skin. Overexposure to UV radiation 11. Specifically, approved protective welding can also cause skin cancer. helmets & goggles, leather aprons, jackets and work boots are worn by all workers  Hazardous when operating any TIG welding plant & Substances equipment. Is it likely that the plant operator or others nearby in the workspace could be exposed to hazardous or toxic chemicals such as oils, hydraulic fluids, greases, coolants, volatile vapours or toxic fumes?

DETE - Organisational Health Unit Issued: November, 2013. V3 Page 5 of 8 Uncontrolled when printed Details of how this will Hazards/Risks Hierarchy of Recommended Yes No be implemented Control Measures ( and any additional controls )

Ergonomics & 1. Where possible, practical welding benches Manual Handling: are planned & adjusted to a comfortable work height thus minimizing any unsafe or excessively strenuous manual tasks. Can the plant be safely operated, in a suitable 2. Sufficient workspace is provided in all location, providing clear & practical workspaces & welding bays to unobstructed access? help ensure unobstructed, safe operation. Poorly designed work stations often necessitate teachers & 3. Floors are regularly cleaned & free of students performing manual excessive waste materials & other tasks involving heavy lifting & extraneous objects. lowering, pushing, pulling or 4. Staff training is provided with regard to carrying, etc. Such tasks then manual handling techniques and contribute to a range of procedures to minimise exposure to these musculoskeletal sprains & hazards. strains for workers.

Explosion & Fire: 1. Fire extinguishers of the correct type are readily available in all workspaces & As a consequence of using positioned near exit doorways. this particular item of plant & 2. Staff training is provided regarding equipment, could anyone be procedures for the correct & appropriate injured by the release of use of fire safety equipment. stored energy triggered by volatile, explosive substances 3. Exits from buildings & other work areas are such as stored gasses, defined & access to them kept clear of vapours or liquids? obstructions. Could fire & explosion also 4. Safety signage is posted clearly denoting result from a build up of wood the location of all fire safety items & dust in the dust extraction emergence exits. system or in confined ceiling spaces?

Additional Control Measures Other Hazards/Risks These would relate to the specific student needs, locations and conditions in which you are conducting your activity.

DETE - Organisational Health Unit Issued: November, 2013. V3 Page 6 of 8 Uncontrolled when printed Approval

Submitted by: Date:

Approved as submitted. Approved with the following condition(s):

Not Approved for the following reason(s):

By: Designation:

Signed: Date:

ITD staff members involved in the use of this risk assessment & the associated plant & equipment:

 Signature: ……………………………….. Date:

 Signature: ……………………………….. Date:

 Signature: ……………………………….. Date:

 Signature: ……………………………….. Date:

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DETE - Organisational Health Unit Issued: November, 2013. V3 Page 7 of 8 Uncontrolled when printed Monitoring and Review This Plant & Equipment Risk Assessment is to be monitored and reviewed annually for a further four (4) years

Review 1: Yes No

 Are allocated risk levels and “Actions Required” unchanged over the past 12 months ?

 Are Minimum Standards and Recommended Control Measures unchanged over 12 months ?  ITD staffing details at this school have remained unchanged over the past 12 months ?

If the responses are “NO” for any question, record current details here, and list all staff changes (with signatures)

Reviewed by: Designation: Signed: Review Date :

Review 2: Yes No

 Are allocated risk levels and “Actions Required” unchanged over the past 12 months ?

 Are Minimum Standards and Recommended Control Measures unchanged over 12 months ?  ITD staffing details at this school have remained unchanged over the past 12 months ?

If the responses are “NO” for any question, record current details here, and list all staff changes (with signatures)

Reviewed by: Designation: Signed: Review Date :

Review 3: Yes No

 Are allocated risk levels and “Actions Required” unchanged over the past 12 months ?

 Are Minimum Standards and Recommended Control Measures unchanged over 12 months ?  ITD staffing details at this school have remained unchanged over the past 12 months ?

If the responses are “NO” for any question, record current details here, and list all staff changes (with signatures)

Reviewed by: Designation: Signed: Review Date :

Review 4: Yes No

 Are allocated risk levels and “Actions Required” unchanged over the past 12 months ?

 Are Minimum Standards and Recommended Control Measures unchanged over 12 months ?  ITD staffing details at this school have remained unchanged over the past 12 months ?

If the responses are “NO” for any question, record current details here, and list all staff changes (with signatures)

Reviewed by: Designation: Signed: Review Date :

DETE - Organisational Health Unit Issued: June, 2013. V3 Page 8 of 8 Uncontrolled when printed