JOB: Welding a broken bottle lifter of a Maheu machine.

TASK( In sequence)

STEPS TAKEN
1. Cutting
a) Connection of the

HAZARDS

ASSOCIATED

MITIGATORY

RISKS

MEASURES

Electric shock

Burns

Wear insulating gloves

Grinder moving parts;

Body cuts;

Wear safety leather gloves;

Hot fragments; Flying

Burns

work suit; safety goggles/face

cutting grinder to
the power source
b) Cutting (Creating
a chuff)
2. Welding
a) Inserting an
electrode in the
electric holder
b) Welding (Joining
the broken parts)

objects
Electric conducting

shield; apron
Electric shock

Wear insulating gloves

Burns; Arc eye;

Wear work suit; welding

Property

helmet; Remove all

damage;

combustible materials 11m

Fatality;

away from the working area/

Respiratory

cover combustible materials

problems

with non-combustible

parts
Excessive heat;
Welding arc; Fire;
Fumes

material; In case of fire, use

standby fire equipment and
nearest fire alarm; If the
working area is confined, use
c) Removal of weld
chips
3. Grinding

Sharp and hot objects

Hand cuts ;

artificial ventilation.
Use chipping hammer; Wear

Flying objects;

burns
Eye injuries;

leather gloves
Wear face shield; Remove all

Grinding sparks

Fire

combustible materials 11m

away from the working area/

cover combustible materials

with non-combustible
material; In case of fire, use
standby fire equipment and
nearest fire alarm; If the
working area is confined, use
artificial ventilation.

PROCEDURE
1. PURPOSE
2. The purpose of this procedure is to ensure control of potential hazards that come with the
process of hot work.
3.

DEFINITIONS
3.1 Hot Work (HW): work that generates sparks or uses an open flame, including
cutting, welding, brazing, soldering, burning, portable gas heaters or spark producing
equipment
3.3 Fire Watch: person/s posted to monitor the safety of hot work operations and
watches for fire

ISSUE A HOT WORK PERMIT

Permit authorizer.
a) Ensure all hazards associated with the proposed hot work job have been
identified, assessed and controlled.
b) Be familiar with the intended tasks
c) Ensure that the area and equipment are made safe before hand over.
d) Make sure that the permit/s is displayed at the work site.
LOCK OUT,TAG OUT AND TRY OUT
To be done by a qualified personnel i.e. Electrician and/ or an Electrical Engineer
together with the worker working on the breakdown machine
Worker
a) Be skilled, qualified, trained and competent to perform the work, including the
use of any personnel protective equipment or rescue equipment
b) Barricade the working area

c) Assess the task

d) The worker should remove butane lighters from their pockets or within the work
area.
e) An adequate number of dedicated fire extinguishers rated for the expected class of
fire must be provided for immediate use in the work area.
f) Remove all combustible materials 11m from the area where hot work is being
conducted. Where it is not feasible, these must be covered with a flame proof
material or acceptable covering.
g) Cover the welding area with a welding shield before the work commences
CUTTING
1. Remove all combustible materials 11m away from the working area/ cover
combustible materials with non-combustible material.
2. Tool inspection. Check whether the moving parts of the cutting grinder are
guarded before use
3. Cover the working area with a shield so that the passerby will not be affected by
the flying objects.
4. In case of fire, use standby fire equipment and nearest fire alarm.
5. Wear proper PPE i.e. work suit, leather gloves, safety goggles/ face shield and
apron.
WELDING
1. Remove all combustible materials 11m away from the working area/ cover
combustible materials with non-combustible material.
2. Tool Inspection. Check for broken electrical cables and electrode holder
before use.
3. Ensure that the cables are barricaded and safe to other workers.
4. Wear insulating hand gloves and safety shoes so as to avoid electric shock.
5. Check the welding machine for correct working currents (A) on power
connection before use.
6. If the working area is confined, use artificial ventilation.
7. Cover the welding area with a welding shield before the work commences.
8. In case of fire, use standby fire equipment and nearest fire alarm.

GRINDING

1. Remove all combustible materials 11m away from the working area/ cover
2.
3.
4.
5.

combustible materials with non-combustible material.

Tool Inspection. Check for broken electrical cable and other defects.
Check whether the moving parts of the hand grinder are guarded.
Cover the area with a barrier/shield before the work commences.
In case of fire, use standby fire equipment and nearest fire alarm.

RECORDS TO BE KEPT
a) Work permits
b) Inspection records
c) Training records