P. & I. Pascoe Limited

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1 P. & I. Pascoe Limited Significant Hazard Register and Safe Operating Procedures (SOP s) Workshop July 2008

Significant Hazard Register & Safe Operating Procedures WORKSHOP FORK LIFT Crushing from machine Never exceed the rated SWL of the machine Check controls, water, diesel, tyre pressures, and fork

Injury from falling packets and loads Nipping and cutting hazards from: - boom -fork lift Hearing loss from long exposure to noise Keep all parts of the body inside the machine when moving.

2 Significant Hazard Register & Safe Operating Procedures WORKSHOP FORK LIFT Crushing from machine Never exceed the rated SWL of the machine Check controls, water, diesel, tyre pressures, and fork locking pins before use each day. Report all defects. Injury from falling packets and loads Nipping and cutting hazards from: - boom -fork lift Hearing loss from long exposure to noise Keep all parts of the body inside the machine when moving. Keep speeds under 10 km/hr in the open yard and to less than 5 Km/hr around sites, processing and workshop areas. When parked, leave forks on the ground, handbrake on, motor off. No passengers (unless inside a sealed cab when a seat is provided and not during lifting operation). Don t stand on the forks! Loads carried as close to the ground as practicable. Always check people are clear and the load is stable before moving off. Never travel with loads raised high into the air to provide vision. When moving large objects attach taglines to allow staff a safety zone when guiding loads into place Travel down ramps and steep roadways backwards when laden. To safeguard load, tilt mast backwards. TRAINER: OSH Approved Forklift Training or NZ Forklift Operators License (F endorsement). Watch for rear end swing and slow down before changing direction. Avoid sudden movements, especially when load is raised. PERSON PROTECTIVE EQUIPMENT REQUIRED Ear muffs, Safety Boots, Overalls Page 1

Significant Registers and Safe Operating Procedures IMPLEMENTS GRINDER Injury Cuts, flying material

from sparks PERSONAL PROTECTIVE EQUIPMENT REQUIRED Eye, hearing and respiratory protection as required

3 Significant Registers and Safe Operating Procedures IMPLEMENTS GRINDER Injury Cuts, flying material Catch loose clothing Repeated use (OOS) injury Failure of bit or disc Noise Breathing in fumes Fire from sparks PERSONAL PROTECTIVE EQUIPMENT REQUIRED Eye, hearing and respiratory protection as required Training: to select, inspect, mount, and care in use. 1. Inspect wheel / disc for chips or cracks 2. Do not use any worn / damaged disc. 3. Rev s per minute on grinding wheel MUST be greater than the rated speed of the grinder 4. Position wheel guard maximum safety 5. Hands / loose clothing away from belt DO NOT USE: Modified discs Without side handle Without the guard Near flammable materials Australian standard 1788 Bench grinder Needs securing OFF SWITCH Buffing wheel & Belt sander Disc grinder / cutting wheel Page 2

Significant Registers and Safe Operating Procedures WELDING Explosion / Fires O2 under pressure can combust oil & grease [esp. where there is sawdust].

to eyes Electrical Safety PERSONAL PROTECTIVE EQUIPMENT REQUIRED Welding helmet with arc flash filter, long sleeved flame proof overalls, gloves, apron, respiratory protection, hearing protection

4 Significant Registers and Safe Operating Procedures WELDING Explosion / Fires O2 under pressure can combust oil & grease [esp. where there is sawdust]. - avoid flammable gas & solvents Burns hot metal / sparks Toxic Fumes - beware Galvanized Metal - beware coatings on metal - from welding process -from paints - from degreasing chemicals Flash Harm to eyes Electrical Safety PERSONAL PROTECTIVE EQUIPMENT REQUIRED Welding helmet with arc flash filter, long sleeved flame proof overalls, gloves, apron, respiratory protection, hearing protection also see OSH Booklet Hot work on Drums & Tanks. Avoid welding above the pit, if possible Keep 10 meters away from combustibles NEVER substitute O2 for compressed air. Fire extinguishers available & visible. Staff trained in their use. BEWARE welding containers that have held combustibles - e.g. petrol / white spirit / linseed oil / soap / acids that react with metal to produce hydrogen / Wear eye protection & cover bare skin Assume EVERYTHING is hot Ventilation: - Extraction fans - Doors wide open / large volume work space Create Less fumes: - MMAW > MIG > TIG - Keep current at minimum possible - Use electrodes that create least fumes - Don t work with fumes rising into face Wear PPE protective visor with Arc Flash filter Electrical Safety with transformer [isolating switch] Tag tested annually Don t use welders with frayed or cracked leads Use appropriately rated power boards Secure cylinders Page 3

Significant Registers and Safe Operating Procedures SAFE USE OF WELDING GASES PERSONAL PROTECTIVE EQUIPMENT REQUIRED: Welding helmet with arc flash filter, long sleeved flame proof overalls, gloves,

5 Significant Registers and Safe Operating Procedures SAFE USE OF WELDING GASES PERSONAL PROTECTIVE EQUIPMENT REQUIRED: Welding helmet with arc flash filter, long sleeved flame proof overalls, gloves, apron, respiratory protection, hearing protection. Oxy acetylene gas cutting equipment HAZARD: Generation of gases - Nitrogen dioxide from arc welding [irritates eyes / throat ] High dose fatal. - Phosgene [irritates skin] From degreasers left on metal. High dose fatal. - Phosphine [irritate eyes nose & skin] When phosphate rust proofing on steel is welded. High concentrations damage kidneys - Ozone [headache & chest pain / irritates mucous membranes]. From UV rays in air when arc welding. Training: See Booklet TN7 : Bottles: Correctly labeled Stored in ventilated area Well secured against falls Fuel gas [BBQ] & O2 cylinders stored separately Acetylene cylinders stored upright Stored away from electrical apparatus & heat source Examine cylinders for defects [rusting / leakage] Mark as empty & store with valves closed Equipment: Free of oil or grease BLACK = inert gases RED = acetylene hoses BLUE = oxygen No copper piping with acetylene Ensure cylinders are secure Usage operators need to know: How to attach equipment How to leak test Correct procedure for lighting gas torches Close valves & release gas before removing regulators Don t use O2 to dust off clothing Don t use O2 to sweeten the air WELDERS = ONLY those endorsed by Peter / Danny. Page 4

SECURE CLAMP IN PLACE WEAR SAFETY GLASSES Know what the machine does How it works How to start & stop it

6 Significant Hazard Register & Safe Operating Procedures Drill Press Stop buttons Injuring Hands - crush injury - flying debris - foreign body in eye Electric Shock SAFE OPERATING PROCEDURE OPERATORS NEED TO KNOW: KEEP WORK SECURE CLAMP IN PLACE WEAR SAFETY GLASSES Know what the machine does How it works How to start & stop it Location & operation of controls PERSONAL PROTECTIVE EQUIPMENT REQUIRED Safety Boots, Safety Glasses, Overalls Page 5

Significant Registers and Safe Operating Procedures TOOLS AIR POWERED GREASE GUN Getting pricked with the needle point Injecting grease under pressure 1. Use protective sleeve over needle point 2.

7 Significant Registers and Safe Operating Procedures TOOLS AIR POWERED GREASE GUN Getting pricked with the needle point Injecting grease under pressure 1. Use protective sleeve over needle point 2. Inspect carrier 3. Ensure drum lubricant secure 4. Safe handling when replacing used drums PERSONAL PROTECTIVE EQUIPMENT REQUIRED Gloves DO NOT: Remove protective sleeve Training: inspect, mount, and care in use. LADDERS Falling from height Hard landing Head injury Broken bones CARRY TOOLS SO THAT BOTH HANDS ARE FREE Don t lean against fragile surfaces! Secure ladders Have 2 nd person at foot of ladder if more than 6 m long Top must be 1 m above landing unless hand holds avail. Place on level surface / firm footing / not slippery Ensure stable angle 4 units up for 1 out Extenders need to overlap by 3 rungs Control for vehicles / stock / electric wires Regular maintenance so ladders in good order PERSON PROTECTIVE EQUIPMENT REQUIRED Covered Shoes Page 6

hazard Overhead hazard Wrong height for job - over reaching No grip on ladder Long length of material Standing on top 3 rungs

8 Significant Hazard Register & Safe Operating Procedures Ladders Right Height Good Grip Stand off used Flat shoes Clean steps At least 3 rungs overlap Ladder undamaged Adult at foot of ladder Two non slip feet At correct angle Firm level base Electrical hazard Overhead hazard Wrong height for job - over reaching No grip on ladder Long length of material Standing on top 3 rungs Slippers Ladder overlaps by one rung Slippery steps Damaged stile & rung Non slip foot missing Unstable surface Base too far from wall Page 7

Significant Hazard Register & Safe Operating Procedures BRAKE RIVETING MACHINE Injuring Hands - crush injury [air operated plunger] Over-inflation - BEWARE burst tyre tube.

$e.g. air hose fracture PERSONAL PROTECTIVE EQUIPMENT REQUIRED Safety Boots, Safety Glasses, Overalls Maintenance: - Check oil levels - Drain air tank regularly - Keep record of service.$

9 Significant Hazard Register & Safe Operating Procedures BRAKE RIVETING MACHINE Injuring Hands - crush injury [air operated plunger] Over-inflation - BEWARE burst tyre tube. Electrical fault Noise hazard OPERATORS NEED TO KNOW: What the machine does Correct settings How to start & stop it Location & operation of foot controls How to read the pressure gauge Likely faults e.g. air hose fracture PERSONAL PROTECTIVE EQUIPMENT REQUIRED Safety Boots, Safety Glasses, Overalls Maintenance: - Check oil levels - Drain air tank regularly - Keep record of service. Automatic cut out at set pressure. How to read the pressure gauge Likely faults e.g. air hose fracture Don t kink hose to cut down air flow use control Running hoses over weakens them Don t use for cleaning or brushing down [beware bare skin]. Page 8

Significant Register and Safe Operating Practice HAZARDOUS SUBSTANCES ENVIRONMENTAL: No OIL DEISEL ANTIFREEZE storm water. BEWARE: contaminates property & ground water.

10 Significant Register and Safe Operating Practice HAZARDOUS SUBSTANCES ENVIRONMENTAL: No OIL DEISEL ANTIFREEZE storm water. BEWARE: contaminates property & ground water. NB: Oil contains heavy metals barium, Chromium, zinc & hydrocarbons. in FIRE / EXPLOSION EXPOSURE is HEALTH RISK / POISONING Effects may be cumulative Effect may be some time in the future REMEMBER: NEVER EAT, DRINK nor SMOKE when handling Hazardous Substances Wash off splashes as soon as they occur Use correct PPE & avoid poisoning through the skin. CONTROLLING THE RISK : Keep accurate inventory of all Hazardous Substances Material Safety Data Sheet (MSDS) FOR EACH All containers correctly labeled Approved collector to remove substances & contaminated containers. Substitute Use safer product where possible Storage Segregate from work area Stock minimum required Keep an Inventory of Hazardous Substances Separate from: WELDING activity, & combustibles. Trained workers Have written instructions on how to HANDLE USE & STORE each substance you use. [Use Hazardous Substances Information Sheet] Correct dilutions / understand adverse effects Trained first aiders. PPE: According to MSDS respirators, filters, waterproof clothing, rubber gloves, waterproof footwear, eye protection. Keep well maintained. Good Wash Facility: Hand wash available Plenty of running water Page 9

Significant Registers and Safe Operating Procedures SAFE USE OF WATER BLASTER : High pressure hoses: One reel either side of wash bay Wall mounted at shoulder height Replace if appear worn or start

11 Significant Registers and Safe Operating Procedures SAFE USE OF WATER BLASTER : High pressure hoses: One reel either side of wash bay Wall mounted at shoulder height Replace if appear worn or start to leak. BEWARE HOT when steam cleaning Turn water taps off at wall when not in use - Pressure building up may force leak or rupture Motor: Electrically powered Diesel powered burner PRODUCES STEAM! BEWARE: HOT STEAM under pressure HAZARD: BURN HAZARD - Hot steam expelled under pressure ELECTRICAL HAZARD - Isolated / Cut out or overload switches PERSONAL PROTECTIVE EQUIPMENT REQUIRED: Gloves, overalls or wet weather gear, eye protection, hearing protection. Usage operators need to know: Turn water first Power on and check pressure settings Hot or cold settings After hot use, turn off heat & run until cool Beware close proximity damage - remove paint - damage rubber - hurt skin / damage eyes Don t point the hose at people Leave hoses lying around Page 10

Hazard Significant Registers and Safe Operating Procedures ENVIRONMENT HOUSEKEEPING Trips Falls Cuts Falling objects Fire Stress Good housekeeping = safety.

HEALTH & HYGIENE Illness RESPONSIBILITY: EVERYONE WEAR THE PROTECTIVE CLOTHING PROVIDED E.G. OVERALLS / GLOVES. ALWAYS wash well in hot soapy water. Respect smoke-free areas.

12 Hazard Significant Registers and Safe Operating Procedures ENVIRONMENT HOUSEKEEPING Trips Falls Cuts Falling objects Fire Stress Good housekeeping = safety. Access and egress MUST BE CLEAR Fire and safety equipment accessible Rubbish and off cuts cleared away RESPONSIBILITY EVERYONE WEAR THE PROTECTIVE CLOTHING PROVIDED E.G. OVERALLS / GLOVES. HEALTH & HYGIENE Illness RESPONSIBILITY: EVERYONE WEAR THE PROTECTIVE CLOTHING PROVIDED E.G. OVERALLS / GLOVES. ALWAYS wash well in hot soapy water. Respect smoke-free areas. Food only eaten in smoko areas. Always wash hands before eating. Cuts or abrasions must be covered Launder work clothes regularly & separately from your domestic wash. Spillage disposed of per procedure considering the environment. Page 11

Significant Hazard Register & Safe Operating Procedures WORKSHOP NOISE Loud sound from excavators / trucks / other traffic Deafness: If you use machinery you may need protection Hearing damage is

General Guideline: If the noise is so load that you have to shout to be understood by someone standing at arms length from you, then you need hearing protection.

13 Significant Hazard Register & Safe Operating Procedures WORKSHOP NOISE Loud sound from excavators / trucks / other traffic Deafness: If you use machinery you may need protection Hearing damage is cumulative & according to exposure. It happens over time. General Guideline: If the noise is so load that you have to shout to be understood by someone standing at arms length from you, then you need hearing protection. NB: Above 115 decibels without protection, instant damage will occur. PERSONAL PROTECTIVE EQIPMENT GUIDELINE Protection Required Noise Source Damage Time Without protection Grade 5 Earmuffs Chainsaw 30 seconds Grade 4 Earmuffs Loud machinery 4 minutes Manual Handling Hazard Commonly results in Back Pain: - Related to incorrect lifting at WORK & HOME - Related to lifting and twisting - From carrying uneven loads - Or carrying awkward loads - Working Too long in the same position Positively Related to: -Posture - Weight - Fitness ALWAYS ASSESS THE RISK PLAN THE LIFT SEEK HELP IF NECESSARY DON T LIFT IT, IF TOO HEAVY BEND KNEES STRAIGHT BACK STAND CLOSE TO THE LOAD REPORT ANY PROBLEMS Page 12

Hazard Significant Registers and Safe Operating Procedures ENVIRONMENT SUNSHINE BURNS Deadly MALANOMA SKIN CANCERS in later life Beware: over exposure to ears, nose, backs hands Plan on avoiding heat

Hats, sunglasses, clothing best Sunscreen to a lesser degree ERGONOMIC INJURY Ergonomic - Muscular Injury Working in the Office Correctly set up work station Good posture Macro & mini breaks while

14 Hazard Significant Registers and Safe Operating Procedures ENVIRONMENT SUNSHINE BURNS Deadly MALANOMA SKIN CANCERS in later life Beware: over exposure to ears, nose, backs hands Plan on avoiding heat of the day if possible Work In shade if possible Always wear a hat DON T LET YOURSELF BURN SUNSHINE EXPOSURE TIME IS A METER HEALTH MONITORING [regular checks] PERSON PROTECTIVE EQUIPMENT REQUIRED Hats, sunglasses, clothing best Sunscreen to a lesser degree ERGONOMIC INJURY Ergonomic - Muscular Injury Working in the Office Correctly set up work station Good posture Macro & mini breaks while working at the computer / avoid repetition Stretches RISK INCREASES WHEN: Too heavy Awkward / bulky / resistant Lifting & twisting Lifting repetitively Reaching out Above your head No hand grips Slippery or uneven surfaces Needing help Poor posture 1. Assess the Risk 2. Avoid the lift if possible [use vehicle / equipment] 3. Divide the lift 4. Plan the lift 5. Back straight 6. Bend knees 7. Load close to body 8. Good posture 9. Be fit NEVER LIFT ANYTHING TOO HEAVY OR AWKWARD Page 13

Significant Registers and Safe Operating Procedures FIRE PLAN FIRE HAZARD: - Smoke inhalation - Heat & burns Extinguishers Need to suit fires caused by: - appliances - switches - power tools - fat or

FIRE PLAN: Warning Systems: Alarm Located Tested monthly Post emergency numbers on wall - 111 The muster point is.

15 Significant Registers and Safe Operating Procedures FIRE PLAN FIRE HAZARD: - Smoke inhalation - Heat & burns Extinguishers Need to suit fires caused by: - appliances - switches - power tools - fat or oil - petrol -kerosene PERSONAL PROTECTIVE EQUIPMENT REQUIRED: long sleeved flame proof overalls, gloves, respiratory protection. Training: Fire Warden Refresher every 6 months. FIRE PLAN: Warning Systems: Alarm Located Tested monthly Post emergency numbers on wall The muster point is.. Highly visible notices Floor Plan showing -exits - muster point - location of Fire Fighting Equipment Equipment: Fire extinguishers checked annually Hose reels checked monthly & when used - used for paper, lumbar, burning plastic Staff participation: Fire Wardens Know their responsibilities 1. Help people to safety 2. Call for help 3. Roll call people at work 4. Look for missing people [only if it is safe] 5. Help the injured 6. Report to the Fire Service 7. Control people until given the all clear The Disability Register is kept Run exit drills SMOKE IN THE BUILDING BEWARE HAZARDOUS SUBSTANCES Page 14

Hazard Identification and Risk Assessment Form. Risk Assessment

Hazard Identification and Risk Assessment Form. Risk Assessment Identification and Assessment Form Assessment Tool & Machine Work General Various injuries (including potential fatalities) All staff complete safety induction programme at the start of the module. instructed