OHS026
1. Completed by: J. Ward & A. Byrne
Safe work procedure
Staff/Student number:
z3203580 & z2081156
The Writing Safe Work Procedures Guideline (OHS027) should be consulted to assist in the completion of this form
Faculty/Division:
School/Unit:
COFA
Document number
Initial Issue date
TRSS
SWP_WOR_25
20/3/2008
Current version
Current Version
Issue date
12/3/2011
Next review date
12/3/2012
2.Safe work procedure title and basic description of activity
Title: Using Oxy-Acetylene for Welding
Description of activity: Used by staff and students in the production of Art and Design
3.List Hazards and risk controls as per risk assessment
Associated risk
assessment
number and
location:
RA_WOR_25,
Tool Room. Metal
Workshop, Ground
Floor, F Block
Hazards
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Noise
Explosion
Hot surfaces
Fumes
Trip hazard
Infrared and
UV radiation
Hot surfaces
Dust
Proximity to
users of other
machines
Users of some
machines may
be working in
the route of
egress
Controls
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The equipment isolated and locked off
Gas bottles stored separately in secure storage.
Welding screens are fitted to the workshop and portable welding
screens are available.
Fume extractors at the workbench and general extraction in the
workshop.
Equipment fitted with flashback arrestors at multiple points in the gas
lines.
Main valves fitted in the gas line are positioned in the Tool Room and
controlled by technical staff only.
No flammable materials in work area.
Signage used (Mandatory, Prohibitive and Warning signage)
Regular maintenance and inspection.
Instruction and competency based training given.
SWP
Machines in close proximity to one another should not be used at the
same time.
Route of egress clearly marked on the workshop floor
Restricted number of users in the workshop at any one time.
Technical staff to ensure that at least one route of egress is free and
available.
Wearing Appropriate PPE.
No loose clothing or jewellery to be worn.
Emergency procedures.
Emergency shower and eyewash installed in workshop
Fire blankets and extinguishers available
4.List resources required including personal protective clothing, chemicals and equipment needed
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OHS026 safe work procedure
Effective date:
Uncontrolled document when printed
Current Version: 3.0 09/08/2010
The above PPE, Oxy-Acetylene Kit, wire brush, pliers or large metal tongs, metal clamps, set square, ball-pein
hammer, welding rod, flux (for brazing techniques only), chalk
5.List step by step instructions or order for undertaking the task
WARNING!!!! YOU WILL NOT BE ALLOWED TO USE THIS MACHINE WITHOUT HAVING COMPLETED THE
APPROPRIATE COMPETENCY TEST.
Before using the Oxy-Acetylene equipment
 Hazard!! Wear safety glasses and insulating gauntlets at all times as well as welding jacket and boots.
 Hazard!! Wear goggles with correct shade.
 Hazard!! Always wear safety glasses at all times.
 Remove or confine loose clothing and Tie hair back.
 Perform a visual and physical inspection of the equipment. Do not use the equipment if there is any sign of damage
and report any damage or malfunction to the technical staff immediately.
Using the Oxy-Acetylene equipment
 Crack open valves momentarily at main taps.
 Hazard!! Check all hoses & fittings for damage.
 Check ‘o’ rings for wear, cracks dust or oil. Hazard! Any oil coming into contact with gases can result in an explosion!!
 Examine the blowpipe for damage and select the correct nozzle for the job in hand.
 Position nozzle and tighten in place.
 Connect the regulator gauges onto the valve seats. Use the spanner to tighten. Oxy – clockwise, Acetylene - anti –
clockwise. (Important! The Oxy – Acetylene system is colour-coded. Oxygen gauges, valves and hoses are always
blue or black. Acetylene gauges, valves and hoses are always red.)
 With the blowpipe valves closed set the correct pressure on the regulator gauges.
 Turn extraction ON and ensure it is positioned near the weld site.
 Check the flow and regulator working pressure on each hose by alternately opening the blowpipe valve and allowing a
small amount of gas to flow from the nozzle. Close the valves.
 With the nozzle pointing away from you open the Acetylene (flammable) gas valve on the blowpipe and light the gas at
the nozzle with a spark lighter. Warning!! Do not use any other ignition source as this can result in serious injury.
 Adjust Acetylene (flammable) gas blowpipe valve until gas ceases to smoke.
 Open the Oxygen valve on the blowpipe slowly and adjust the flame until neutral (Important! Flame adjustment
should always be done gradually to avoid flame ‘snap out’).
 To turn the flame off, ALWAYS turn the Acetylene (flammable) gas OFF first then turn the Oxygen gas OFF at the
blowpipe valve.
 Allow equipment to cool down completely before commencing shut down procedure.
 Turn OFF the Acetylene and Oxygen valves at the main tap.
 Purge each hose of gas alternately: Open the Acetylene valve on the blowpipe to bleed the line free of gas then close
the valve. Open the Oxygen valve on the blowpipe to bleed the line free of gas then close the valve. NB. Always watch
the regulator gauge return to zero while following this step.
 Release the regulator valve (finger loose).
 Remove regulator gauges from taps and replace valve end-caps to valve seats.
 Remove the nozzle from the blowpipe.
 Allow equipment to cool completely before packing all equipment back in the toolbox.
After using the Oxy-Acetylene equipment
 Always leave the workbench and work area clean and tidy
 Return the Oxy-Acetylene equipment toolbox to the Tool Room
 Report any damage or malfunctions to the technical staff immediately.
IF YOU HAVE ANY DOUBTS ABOUT THIS SYSTEM CONTACT THE TECHNICAL STAFF!!
6.List emergency shutdown procedures
 If a flashback occurs, immediately turn off the blowpipe oxygen valve, then the blowpipe fuel gas valve, turn off the
main oxygen valve then the main acetylene valve. Contact the technical staff immediately.
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OHS026 safe work procedure
Effective date:
Uncontrolled document when printed
Current Version: 3.0 09/08/2010
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Press the emergency stop button on the wall of the workshop.
Contact the technical staff immediately
First aid on campus.
Emergency call 9385 6666.
Machines can only be used when technical staff are on duty.
7.List Emergency procedures for how to deal with fires, spills or exposure to hazardous substances
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Consult the UNSW Emergency Procedures booklet and ensure you are familiar with its content.
Contact the Tool Room Technical Staff immediately.
The metal workshop is fitted with the appropriate fire extinguishers.
Spill Kits are located in the Tool Room.
The metal workshop has an emergency shower / eyewash
8.List Clean up and waste disposal requirements
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Clean down bench manually with a dust pan and brush
Remove debris from the floor around the bench
Remove your work from the welding bay after it has cooled.
Dispose of any waste material according to the MSDS. See technical staff if you are unsure.
9.List legislation used in the development of this SWP
NSW OHS ACT 2000, NSW OHS regulations 2001, Safe guarding of machinery AS4024-2006, National standard
for plant, safety in Welding and allied processes AS1674
10.List competency required – qualifications, certificates, licensing, training - e.g. course or instruction:
All people who intend to operate the oxy-acetylene welding equipment MUST BE trained in its safe operation
11.Supervisory approval, And review
Supervisor:
James Ward
Responsibility for SWP review:
Signature:
Date of review:
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OHS026 safe work procedure
Effective date:
Uncontrolled document when printed
Current Version: 3.0 09/08/2010
12.SWP Sign off sheet
SWP name and version:
In signing this section the assessor/ authoriser agrees that the following persons are competent in following this
SWP
Name
Signature
Date
Competent
Name of Assessor/Authoriser
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OHS026 safe work procedure
Effective date:
Uncontrolled document when printed
Current Version: 3.0 09/08/2010
Assessor/Authoriser
signature