Health, Safety and Environment Version 1.0 1 of 43 2009.01.30

Health, Safety and Environment version 1.0 1 of 43 2009.01.30

Course: Health, Safety and Environment

List of content

This project has been funded with support from the European Commission. This publication reflects the views only of the authors, and the Commission cannot be held responsible for any use, which may be made of the information contained therein.

Health, Safety and Environment version 1.0 1 of 43 2009.01.30

MODULE 1 4

Activity Based Training 4

Additional litterature: 7

MODULE 2 9

Health and Safety in Welding 11

The workshop environment 11

Electrical safety 11

Fume 12

Noise 12

Optical radiation 12

Burns and Mechanical Hazards 12

Gas Bottles 12

Welding in difficult situations - outdoors, confined spaces etc. 13

MODULE 3 14

The working environment of the fabrication shop, general hazards, dust, heavy and hot material, cables . 14

Oxyacetylene cutting and heating 16

Safe storage 16

Safe practice and accident avoidance 16

Handling compressed gases 17

Safe practice and accident avoidance 17

Using compressed gases 17

Suitable cutting processes for different types of steel to achieve a suitable cutting surface 18

Flame cutting, Principle and parameters, cutting blowpipes, cutting machines, quality of cut surface 18

Other cutting processes as: plasma, laser, mechanical cutting 18

Safety precautions for cutting (PSS1) 19

Burns and fires, fire prevention, fire fighting 19

MODULE 4 21

Noise hazards. 24

MODULE 5 26

Specific rules and regulations 26

Electric shock 28

Steps to Prevent Electrical Shock 30

Emergency Procedures: 30

UV- and heat radiation 30

Eye hazards 32

Welding fumes 33

Hazardous substances 36

Removal of hazardous welding dust 37

MODULE 6 41

MODULE 7 45

What Is CPR? 45

When Is CPR Needed? 46

Three Parts of CPR 46

Health, Safety and Environment version 1.0 1 of 43 2009.01.30

MODULE 1

Objective:

Have an overview of the course structure and the course methodology for the education and training.

Scope:

· Role and responsibilities of the welding personnel

· Know the most relevant standards for Quality Assurance

· Understand the fundamental ideas behind Activity Based Training (ABT)

Expected results:

· Ensure that the health , environment and safety tasks related to the job are met

· Understand the relevance and fundamentals of health , environment and safety

Activity Based Training

Instead of utilizing the traditional methodology whereby the student moves through a traditional education with theoretical content from A to Z, followed by hands on training, this course will use an Activity Based Training (ATB). With ATB it is understood that the training follow the production activities according the production path of a predefined structure or product. The course will also exploit a blended approach whereby different delivery technologies for the content itself will be used.

The course has been divided into 9 different modules and three of these are modules where the major part of the hours will be utilized for practical work. This means that the students have to participate together in a workshop or laboratory.

This is an important aspect of the methodology itself. When working in an industrial environment the student has to work together with other personnel in order to meet the requirements in quality, time schedules and so forth. The team building effort, its importance for the final product and its importance for the total quality of the production environment must be stressed during the educational process.

In a welding environment today the students will work together with other persons from different cultures, with different educational backgrounds and with different practical experience, which will require a profound focus on flexibility and open minded attitude towards other people. Few if any other educational routes will demand such flexibility to the student itself and to the students behaviour on a short and long term basis.

The course will consist of several job-elements. The figure shows how one work-package is built up of different elements, some are pure theory elements and other is a mixture of theory and hands-on training. The training will be carried out in the workshop, shop, or in a laboratory. Video streaming and/or videoconferencing will be used in Shop/Theory packages. The topics for health, environment and safety will be structured in the same way and will follow the production structure.

Work Package.

A work package might contain several job elements. A work package is a complete documentation package of specific activities that must be mastered in the welding industry in order to handle the whole production process. It contains at least the following information:

i. Drawing of the structure to be fabricated

ii. Work description with which methods shall be used in the production

iii. Work description with process description of the work process for reaching the target and the knowledge required

iv. Quality assurance requirements for the ingoing elements

v. Quality assurance description of the outgoing elements

vi. Work package description for the work to be done

vii. Reference to available resources for the work

viii. Reference to environmental resources or requirements or restrictions

ix. Requirements for knowledge, prerequisite or knowledge that has to be obtained

x. Cooperation strategy with other in a defined group or to related groups

However, some basic prerequisite knowledge must be mastered by the production staff in order to follow the knowledge requirements. The knowledge and competence requirements include:

·Ability to work in a multicultural environment with the colleagues due to exchange of mobile personnel across borders and among mechanical industry companies

·Ability to understand and communicate the content in the job packages to the colleagues in a multilingual working environment

·Ability to understand his/her responsibility in the production chain and to communicate the need for knowledge.

·Ability to search for relevant learning and training material when needed.

·To understand how a process plan might be visualized by utilizing a project plan.

A general design of a learning element. This element consists of both theoretical content as well as practical work. We can also see that the practical task, when completed shall be verified by the student as well as by a 3-part. This will both ensure that the student feel responsible for the part itself, but also be aware of the quality assurance aspect which is very important withing the welding activities. This is a simplified design where no loops are included in the process flow.

A central philosophy within fabrication is that the person who produce a product shall not be the one carrying out the quality control of the same product. To establish the same methodology in education one aims at introducing an alternative production flow whereby the product alternate between students or student groups.

A product is alternating between students during the fabrication process. When produced by student A at a certain stage then student B will carry out the quality control of the part. Student B will then use the part from A in his own production and then transfer it back to A for the following quality control.

This means that the students shall be familiar with and use the definitions and actions that are common in the industry. It will consequently be mandatory to switch the objects for this purpose in order to avoid that a person verifies himself. If defects or non-conformance is found then the necessary corrective actions have to be carried out by the student.

The use of objects should reflect the typical industry environment that is domination in the area where the course is held in order to create a more relevant training domain. But when this is done, then he other examples and references in the material should be selected from a similar industrial background in order to make tis relevant fro the student .

For the course health, environment and safety the same structures will be used as described before. We will follow the production process and add and discuss the elements as we move along the production process as such.

Delivery.

The structure described here is a structure that can be used in different environments. The structure has not been designed for a special delivery method. However, when that has been said, it is possible to use a highly structured an d rigid structure whereby you may control an verify all steps of the student,

If that is the correct way of carrying out the course is of course another question.

The structure that follows is a an idea of which elements that a course should contain, if its running as a web course or if its running as a face-to face course without having access to the web itself.

Additional litterature:

Page / Title / Comment /

Table with reference literature to be read in addition to the course documentation for the individual modules. This table to be compiled according to the national availability of reference literature. This table has to be created by the course organizer because the reference material may vary.

MODULE 2

Objective:

Know how to perform welding activities in the fabrication shop in a safe manner.

Scope:

lThe working environment of the fabrication shop; general hazards, dust, heavy and hot material, electrical cables

lWelding in the fabrication shop; protection of other workers from welding hazards,

lGeneral ventilation to minimise background pollution levels from welding hazards,

Expected results:

Know the general hazards in a fabrication shop.

Know your duties and responsibilities related to health, environment and safety

General.

Safety in welding starts before the welding itself. Some of the key elements in the company strategy for environment and safety can be listed as follows as the managements tasks and responsibility:

1- The Safety Analysis during the welding activities/processes of the Company;

2- The Safety management programmes;

3- Structure and responsibility;

4- Training, awareness and competence of personnel;

5- The Health, Safety and Environment Handbook (HSE), documentation and document control;

6- The control of the elements implemented for Safety purpose;

7- Emergency situation control;

8-Nonconformities, preventive and corrective actions.

These objectives and tasks shall be clearly identified and cared for as procedures and actions that are clearly defined for all personel invoøved in the management and fabrication itself.

The company recognise that you have the necessary professional qualifications, competencies, skills and experience to fulfil your role within the company but in order to make sure you are aware of recognised HSE and security best practice you should also be provided with specific instructions and guidance on the particular features and activities of your new worksite.

The worksite manager or supervisor is responsible for arranging your ‘safety induction’ as soon as possible after your arrival. Your introduction shall be in accordance with the company Introduction Policy and may include the following issues:

· Organisation of the worksite – roles and responsibilities.

· The emergency plan and its location.

· Emergency alarms and responses.

· Overview of work areas, ‘no-go’ areas and general traffic areas.

· Muster points.

· Escape routes.

· Survival craft and equipment.

· Fire fighting equipment.

· First aid treatment and location of equipment.

· Safety signs and their meaning – first aid, warnings etc.

· Identification of safety representatives.

· Review of safety noticeboard.

· Documentation and procedures.

· Hazard identification and risk assessment system at the site.

· Hazardous areas and precautionary measures.

· Confined space working.

· Handling of dangerous substances.

· Protective clothing, equipment and what you must use in your job.

· Reporting of incidents, damage and injuries.

· Action in the event of incident, damage or injury.

· Reporting of safety observations.

· Worksite waste disposal policies.

· Worksite security procedures.

All incidents are preventable. You choose yourseself what type of risks you are encontering by deciding your work procedure, your attitude, your habits...

· Do it safely or not at all

· There is always time to do it right

· When in doubt, find out

Your duties and responsibilities.

Your job description specifies your work duties and responsibilities, but you also have a duty to ensure the safety and welfare of you and your work colleagues as well as preventing damage to equipment and the environment.

To make sure that all work to the same basic standardsthen the following tasks is also your responsibility:

· Learn, understand and work to outline instructions set out in the HSE handbook.

· Read and understand the procedures listed in the handbook.

· Work safely in accordance with the security processes and specific project procedures; seek help from your supervisor if you are unsure.

· Think about the hazards and risks you and others may be exposed to before you start any task and take the necessary precautions to minimise these risks.

· Do not take short cuts or become complacent with regard to safety in carrying out your duties.

· Stop or shut down any activity or operation which is unsafe (including those of contractors).

· Report promptly all unsafe conditions and practices (including those of contractors) to your supervisor.

· Report all injuries, no matter how minor, to your supervisor or the medic promptly.

· Perform your tasks safely, with regard for your own personal safety, the safety of fellow workers, and the protection of the environment and company property.

· Always use the proper safety equipment and keep to safe work practices and established safety standards.

Safe Performance Self-Assessment. Before beginning any activity/task/job, after an incident or near miss, any unusual circumstances, then:

· Assess the risk

· What could go wrong?

· What is the worst thing that could happen if something does go wrong?

· Analyze how to reduce the risk

· Do I have all the necessary training and knowledge to do the job safely?

· Do I have all the proper tools and personal protective equipment?

· Take necessary action to make sure the job is done safely!