FIELD WELDING Networks Safeguard Safe Work Method Statement

Document: APA HSE GP 08.02 Tx Version: 0.01 Date: 04/03/2013 Review by: 26/03/2014 Page 1 of 13 pages

SAFE WORK METHOD STATEMENT – FIELD WELDING

HSE NET NAT SWMS APAND00032

Principal Contractor (PC)

APT AM Holdings Pty. Ltd.

[ABN] 95124754383

APA Group

Level 19, HSBC Building

580 George Street

Sydney NSW 2000

State Representative :

Subcontractor

Person responsible for reviewing & approving the SWMS

John Ferguson

Executive Manager, Networks

Phone 02 9693 0057

Signature and Date Sign: Refer to Approval Sign off Sheet APADN00020 Date: 26/06/2013

Date SWMS provided to PC 04/03/2013 Provided to: Robin Gray

Work Description

SAFE WORK METHOD STATEMENT

Various welding and fabrication works completed in the field

Project Reference

[Project ID, title or equivalent]

Work Location /Address Scheduled work locations Person Responsible for ensuring compliance with SWMS on site

Supervisor Fabrication Services

The following personnel who have consulted and assisted in the development of this SWMS

Heath Lynch, Daniel Reid Review date for this SWMS March 2014

FIELD WELDING Networks Safeguard Safe Work Method Statement

Document: APA HSE GP 08.02 Tx Version: 0.01 Date: 04/03/2013 Review by: 26/03/2014 Page 2 of 13 pages

PERSONNEL SITE CONTENT

Required Supervision Responsible onsite supervisor

Permit acceptor

AS1796 Qualified welding supervisor (as required)

Permit to Work & other Approval Requirements

Hot work in hazardous zone (as required)

Confined space entry (as required)

Excavation (as required)

Hot tap (as required)

Required Qualifications

Trade Certificates

Weld Certificates

Weld Procedure Qualifications

Welding Supervisor (AS1796)

Experience in welding processes

Experience in pipe fitting

Plant, Equipment, Materials

Grinders / Buffer

Slings

Crane

Welding Rig

Oxy / Acetylene - Portable

Hand Tools powered and unpowered

LPG / Oxyacetylene / Propane Gas Torch

Electrode hot box

Pipe stands

Jacks

Bonding straps / Earth stakes

Neon tester (Volt finger)

Lighting

Gas detector

DN20 – DN300 carbon steel pipe

DN8 – DN300 carbon steel fittings e.g. tees, elbows, reducers etc.

Flat bar – steel

Plate – steel

RHS – Steel

SHS - Steel

Required Training

APA induction Card or Short term induction

Construction Industry General Induction

Workplace Specific Induction (if required)

Induction in to this SWMS

Induction to APA JHEA

Hazardous Substances

Refer to SDS Register in welding and steel crew vehicles

FIELD WELDING Networks Safeguard Safe Work Method Statement

Document: APA HSE GP 08.02 Tx Version: 0.01 Date: 04/03/2013 Review by: 26/03/2014 Page 3 of 13 pages

Personal Protective Equipment (PPE)

High Visibility Clothing – Day and Night MANDATORY

Safety Gloves (as required)

Safety Glasses Clear and Sunglasses MANDATORY

Hearing Protection – Earmuffs / Earplugs (as required)

Safety Boots - Steel Cap MANDATORY

Protective Clothing – Must meet and be used as per APA Operations Field Book Procedure 5206

Safety Helmet MANDATORY

Sun Lotion (as required)

Sun Hat (as required)

Fire retardant clothing (as required)

Welding shields (as required)

Emergency Procedures and Equipment

SAOP

Fire extinguishers

Job rescue plan (as required)

Weld repair fittings (as required)

FIELD WELDING Networks Safeguard Safe Work Method Statement

Document: APA HSE GP 08.02 Tx Version: 0.01 Date: 04/03/2013 Review by: 26/03/2014 Page 4 of 13 pages

REFERENCES ASSOCIATED DOCUMENTS

Work Health & Safety Act 2012

Work Health & Safety Regulations 2012

Work Health & Safety Plant Code of Practice

Work Health & Safety Risk Management Code of Practice

Work Health & Safety Noise Code of Practice

AS 1742.3:2009

AS2885.2:2007

AS3992:1998

APA JHEA

APA traffic management check/plan Book

APA Operations Field Book

Safeguard

Approved APA welding procedures

Step No.

What are the tasks involved? in order of job sequence

Hazards/risks What can happen and how can it happen?

Raw Risk Controls to be implemented to reduce risks What will be done to ensure zero harm?

Residual Risk Person responsible Who will make sure it happens?

Break the job down into steps. Each step should accomplish some major task and be in a logical sequence

Specify the potential hazards associated with each step and risks to health, safety and the environment. Examine each to find possibilities that could lead to an incident.

Assess the raw risk without controls

Describe the measures to be implemented to eliminate or control the risks. Describe how these measures are to be implemented, monitored and reviewed.

Assess the residual risk with controls

Specify Person(s) Responsible

1. Site setup

Injuries caused by ingress and egress of excavations due to depth and awkward setup

Possible damage to assets due to confined awkward work area - burn through

Heat exhaustion / stress due to working outside

Electric shock from stray currents in pipeline

Electrocution from lightning strike

Damage to electrical cables

Injuries caused by traffic

Manual handling causing slips / trips / strains / falls

High

(Electrocution)

High

(Manual handling)

Review PPE requirements

Ensure all excavations provide sufficient room to carry out welding. All excavations to be benched, shored or battered if over 1.5m in depth or unstable conditions

Ensure appropriate permits are in place ie Hot works

Check for bushfire restrictions

Ensure all excavations are dry and lined with gravel

Provide shade over work area

Ensure frequent breaks in hotter conditions

Negligible (Electrocution)

Minor

(Manual handling)

Steel works crew

Welders

Welding supervisor

Steel works personnel

FIELD WELDING Networks Safeguard Safe Work Method Statement

Document: APA HSE GP 08.02 Tx Version: 0.01 Date: 04/03/2013 Review by: 26/03/2014 Page 5 of 13 pages

Cool water available onsite

Test pipeline for stray current prior to works using approved volt finger

Attach earth bonding straps to pipeline

Check weather in advance and do not work during electrical storm

Ensure traffic exclusion zone is setup around welding area (use approved barriers)

Lifting aids / dual lift to be used

Safety Signage to be located around any excavations

General site housekeeping to be performed throughout the works

2. Cutting material (oxyacetylene / saw / grinder)

Injury from cutting equipment

Noise exposure causing hearing damage

Sparks resulting in fire hazard

Potential fall / crush from material rolling or falling

Airborne debris from cutting processes

Electric shock from power tools

Fire / Explosion resulting in burns

Fume inhalation resulting in respiratory complications

Molten Metal causing burns

Heat stroke / exhaustion

Slips, Trips, Falls resulting in injury

High

Plant risk assessments completed outlining the machinery hazards

Job setup to separate heating zone from gas supply hoses to avoid gas hose damage

Check for zero gas in pipe work / hoses and in the atmosphere using gas detector

No loose clothing / jewellery to be worn

Machine guarding where applicable

Electrical test and tag of all relevant equipment

Equipment maintenance completed

Trained and competent personnel

Moderate

Steel works crew

Welders

Welding supervisor

FIELD WELDING Networks Safeguard Safe Work Method Statement

Document: APA HSE GP 08.02 Tx Version: 0.01 Date: 04/03/2013 Review by: 26/03/2014 Page 6 of 13 pages

Strains and sprains

Injury caused by pipe setup and ergonomics

Manual tasks resulting in muscular pain and injury

Disruption to other services from cutting

Impact injury caused by grinder catching on pipe work not sufficiently secured

Safety Screens where applicable

Fire extinguishers located near works

APA Group JHEA to outline all hazards and completed prior to works

APA Hazardous task permit (as required)

Extraction fans

Cold water available

Physical Barriers / Exclusion Zones

Safety Signage

General site housekeeping to be performed throughout the works

Lifting aids / dual lift to be used(as required)

Material to be adequately supported and fixed to prevent material moving during works

Exclusion zone to be implemented around pipe cutting operations

Nine inch grinders are not to be used

Residual Current Device (RCD)

3. Drilling (power hand tool)

Personal injury from drilling equipment

Noise exposure causing hearing damage

Sparks resulting in fire hazard

Potential fall / crush from material rolling or falling

Airborne debris from drilling processes potentially resulting in eye injury and example of this would be hot and sharp swarf

High

Plant risk assessments completed outlining the machinery hazards

Job setup to separate drilling zone from electrical supply cables to avoid cable damage

No loose clothing / jewellery to be worn

Electrical test and tag of all relevant equipment

Equipment maintenance completed

Minor

Steel works crew

Welders

Welding supervisor

FIELD WELDING Networks Safeguard Safe Work Method Statement

Document: APA HSE GP 08.02 Tx Version: 0.01 Date: 04/03/2013 Review by: 26/03/2014 Page 7 of 13 pages

Electric shock from power tools

Burns from hot material

Fume inhalation from lubricants resulting in respiratory complications

Slips, Trips, Falls resulting in injury

Injury caused by pipe setup and ergonomics

Manual tasks resulting in muscular pain and injury

Entanglement in drilling operation from loose items

Impact injury caused by drill catching on pipe work not sufficiently secured

Strains and sprains

Heat stroke / exhaustion

Non-lockable hand drills to be used

Fire extinguishers located near works

APA Group JHEA to outline all hazards and completed prior to works

Safety Signage

Trained and competent personnel

General site housekeeping to be performed throughout the works

Correct restraint of work piece

APA Hazardous task permit to be initiated when completing in a hazardous area (as required)

MSDS available and current

Residual Current Device (RCD)

Frequent rest breaks during hotter conditions

4. Grinding / Buffing

Personal injury from grinder equipment

Noise exposure causing hearing damage

Sparks resulting in fire hazard

Potential fall / crush from material rolling or falling

Airborne debris from grinding/buffing process potentially resulting in eye damage

Electric shock from power tools

Burns from hot material

Fume inhalation from coatings being removed

Slips, Trips, Falls resulting in

High

Intermediate based on AS2885 risk assessment

Plant risk assessments completed outlining the machinery hazards

Site risk assessment to be performed outline any network risks

Nine inch grinders are not to be used

Job setup to separate grinding zone from electrical supply cables

No loose clothing / jewellery to be worn

Fire retardant clothing

Machine guarding where applicable

Electrical test and tag of all relevant equipment

Moderate

Intermediate based on AS2885 risk assessment

Steel works crew

Welders

Welding supervisor

FIELD WELDING Networks Safeguard Safe Work Method Statement

Document: APA HSE GP 08.02 Tx Version: 0.01 Date: 04/03/2013 Review by: 26/03/2014 Page 8 of 13 pages

injury

Injury caused by pipe setup and ergonomics

Heat stroke / exhaustion

Manual tasks resulting in muscular pain and injury

Entanglement from grinding / buffing operation

Impact injury caused by grinder catching on pipe work

Strains and sprains

grinding into live gas pipe resulting in leak and potential ignition

Reduced wall thickness of pipeline increasing risk of burn through and pipe integrity

Disruption to other services from grinding

Equipment maintenance completed

Trained and competent personnel

Approved welding procedures

Qualified welders to procedures

Safety Screens

Frequent rest breaks during hotter conditions

Fire Extinguishers located near works

APA Group JHEA to outline all hazards and completed prior to works

Cold water available

Physical Barriers / Exclusion Zones

Safety signage

General site housekeeping to be performed throughout the works

Lifting aids / dual lift to be used

Correct restraint of work piece

APA Hazardous task permit (as required)

Residual Current Device (RCD)

Design and Engineering approval

Attach earth bonding straps to pipeline

Check weather in advance and do not work during electrical storm

Welding repair clamps

5. Heating (LPG, Oxyacetylene)

Fire / Explosion

Burns from heating torches

Fume inhalation from pipeline coating

Gas leak from cylinder

Heat stroke / exhaustion

High

Soap test all pressure hose connections

Job setup to separate heating zone from gas supply hoses

Trained and competent personnel

Approved welding procedures

Moderate

Steel works crew leader

Welders

Welding supervisor

FIELD WELDING Networks Safeguard Safe Work Method Statement

Document: APA HSE GP 08.02 Tx Version: 0.01 Date: 04/03/2013 Review by: 26/03/2014 Page 9 of 13 pages

Noise exposure causing hearing damage

Potential fall / crush from material rolling or falling

Slips, Trips, Falls resulting in injury

Injury caused by pipe setup and ergonomics

Manual tasks resulting in muscular pain and injury

Uncontrolled pressure release of gas supply cylinders resulting in personnel injury

Qualified welders to procedures

Flash-back arresters installed

Equipment maintenance completed

SDS available and current

Physical separation from other flammable materials

Braided hoses for LPG torch

Fire retardant clothing

Fire extinguishers located near works

APA Group JHEA to outline all hazards and completed prior to work

APA Hazardous task permit (as required)

Cold water available

Frequent rest breaks during hotter conditions

Physical barriers / exclusion zones in place

Safety signage

General site housekeeping to be performed throughout the works

Lifting aids / dual lift to be used

Certified cylinders and in date

Correct and secure storage of all cylinders

Gas detector to be onsite

6.

(Manual Metal Arc Welding, Gas Tungsten Arc Welding, Gas Metal Arc Welding) Engine driven (mobile) or electric driven

Welding flash (eye burns)

Noise exposure causing hearing damage

Sparks resulting in fire hazard

Potential fall / crush from

High

(Electrocution)

High

Qualified weld procedures and supervision.

Qualified welders to procedures

Lock-out and tag-out procedure

Moderate

(Electrocution)

Minor

Steel works crew leader

Welder

Welding supervisor

FIELD WELDING Networks Safeguard Safe Work Method Statement

Document: APA HSE GP 08.02 Tx Version: 0.01 Date: 04/03/2013 Review by: 26/03/2014 Page 10 of 13 pages

(static). material rolling or falling

Electrocution from welding current

Ignition of gas in the event of a burn through resulting in potential burns

Fume inhalation resulting in respiratory complications

Molten Metal / weld material causing burns

Heat stroke / exhaustion

Slips, Trips, Falls, Strains resulting in injury

Injury caused by trench setup and ergonomics

Manual tasks resulting in muscular pain and injury

Electric shock from stray current in pipeline

Electrocution from lightning strike

(Welders flash)

Intermediate based on AS2885 risk assessment

Job setup to separate welding zone from electrical supply cables

Anti-flash glasses for welding assistant and supervisor

Fire retardant clothing

Electrical test and tag of all relevant equipment

Equipment maintenance completed

Trained and competent personnel

Fire extinguishers located near works

APA Group JHEA to outline all hazards and completed prior to work

APA Hazardous task permits (as required)

Cold water available

Frequent rest breaks during hotter conditions

Physical Barriers / Exclusion Zones in place

Safety Signage

Housekeeping

Lifting aids / dual lift to be used

Correct restraint of work piece

SDS available and current

Voltage Reduction Devices (VRDs)

Residual Current Device (RCD)

Breathing apparatus where applicable

Galvanising removed before welding

Welding screens to be positioned around the welding area

Design and Engineering approval

(Welders flash)

Intermediate based on AS2885 risk assessment

FIELD WELDING Networks Safeguard Safe Work Method Statement

Document: APA HSE GP 08.02 Tx Version: 0.01 Date: 04/03/2013 Review by: 26/03/2014 Page 11 of 13 pages

to be completed

Attach earth bonding strap to pipeline

Check weather in advance and do not work during electrical storm

7.

Deviation from this Safe Work Method Statement

Miscommunication by all parties onsite.

High

STOP all work activities

Ensure task and equipment is made safe

Hold a tool box meeting and record and adjust

Complete JHEA for variations from work method – obtain approval from site representative.

Authorised by competent person, supervisor or HSE Advisor

Sign off on changes prior to the recommencement of work

Moderate

Steel works crew leader

Welders

Welding supervisor

FIELD WELDING Networks Safeguard Safe Work Method Statement

Document: APA HSE GP 08.02 Tx Version: 0.01 Date: 04/03/2013 Review by: 26/03/2014 Page 12 of 13 pages

Declaration by contractors and workers - I have been given the opportunity to comment on the content of this SWMS. - I have read and understand how I am to carry out the activities listed in this SWMS. - I have been supplied with the personal protective equipment identified on this SWMS and I have been given training in the safe use of this equipment. - I have read and understand the requirements set out in the material safety data sheets for the hazardous substances identified in this SWMS

Consultation & Review Sign Off Analysis of Training / Skills or Competencies Required

Training / Skill / Competency Required to Complete the Work Safely

Gen

eral

Ind

ust

ry

Ind

uct

ion

Pro

ject

Sp

ecif

ic

Ind

uct

ion

[ Li

st o

ther

s]

A = All employees are required to hold. % of personnel required to hold

A A

Number of personnel required to hold

Name Position Signature Date Training / Skill / Competency held by employee – tick () – evidence must be available

FIELD WELDING Networks Safeguard Safe Work Method Statement

Document: APA HSE GP 08.02 Tx Version: 0.01 Date: 04/03/2013 Review by: 26/03/2014 Page 13 of 13 pages

Risk Assessment CONSEQUENCE

RISK RANKING ACTION REQUIRED

Negligible Work can proceed once risk controls identified and implemented

Minor Work can proceed once risk controls identified and implemented

Moderate Work can proceed once supervisor has confirmed process has been adequately followed and risk controls identified and implemented

High Reduce risk to at least moderate or to ALARP through additional controls. Activity must not commence without Management approval

Extreme Activity must not commence. Reduce risk to at least moderate or to ALARP through additional controls.

HSE First aid treatment only with the ability to return to work immediately

External medical treatment but excluding hospitalisation with the ability to return to work the next work day

Injury or illness requiring hospitalisation and resulting in the inability to return to work the next day (LTI

Permanent partial disability

Fatality OR permanent total disability

Multiple fatalities

Environment Limited impairment to minimal area of low significance

Short-term (<12 months) temporary impairment to the biological or physical environment of a very localised area (<0.1ha)

Prolonged (<5 years) reversible impairment to the biological or physical environment of a localised area (<1ha) which is easily rectified and which does not affect ecosystem function

Uncontrolled off-site release or event. Reversible prolonged impairment to the environment but which does not affect ecosystem function

An uncontrolled off-site release or event in wide area resulting in reversible long-term environmental impairment of ecosystem function

Uncontained, long-term serious environmental degradation OR permanent impairment to ecosystem function or habitat

LIK

ELIH

OO

D

Probability Historical Descriptor LEVEL 1 LEVEL 2 LEVEL 3 LEVEL 4 LEVEL 5 LEVEL 6

At least once per year

Is expected to occur in most circumstances

Frequent Minor Moderate High Extreme Extreme Extreme

At least once every 1 to 5 years

Expected to occur infrequently

Likely Minor Moderate High High Extreme Extreme

At least once every 5 to 10 years

May occur occasionally

Occasional Minor Minor Moderate High High Extreme

At least once every 10 to 50 years

Might occur at some time

Possible Negligible Minor Moderate High High High

At least once every 50 to 100 years

Could occur at some time but not considered likely

Unlikely Negligible Minor

Moderate Moderate High High

Less than once every 100 years

Conceivable but only in exceptional circumstances

Improbable Negligible Negligible Minor Moderate Moderate High