Hazard Identification, Risk Assessment & Safe Working Procedure For

Hazard Identification, Risk Assessment & Safe Working Procedure for “Use of Reciprocating Workshop Saw ”

Project Title:
Site Address: / Cardiff Road, Barry, South Glamorgan, CF63 2YL
Client: / Dow Corning Ltd
PO Number:
Work Location:

Assessed By:

Print Name / Signature / Date Assessed / Assessment Review Date
Paul Bunyan / / 20/04/2014 / 19/04/2015

Approved By:

Print Name / Signature / Date Approved
Richard Jenkins / / 24/04/2014
Steve Tossell / / 24/04/2014
Physical Hazards / Y / Physical Hazards (Continued) / Y / Fire Hazards / Y
Airborne Dust / Fumes / Explosive Materials
Access / Egress / Flammable / Combustible Materials
Adverse Weather Conditions / Flammable Atmospheres
Aggression/Violence / Pyrophoric Material
Bullying / Sources of Ignition
Collapse of Equipment / Materials / Static Electricity
Confined Space Entry
Crane Movements / Lifting
Display Screen Equipment
Drowning
Electricity - Electric Shock / Burns / 
Entanglement / 
Equipment / Materials /  / Other Hazards – Specify Below / Vulnerable Groups
Falling Objects / Materials from Height / Environment - Waste Disposal /  / Disabled Workers
Falls from Height (Working at Height) / Process Pipework / Expectant and Nursing Mothers
Gas Cylinders / Impulse Lines / Tubing / Lone Workers / 
Gasses / Young Persons
High Pressures
High Ambient Temperature
Hot Surfaces / 
Housekeeping / Slips, Trips & Falls / 
Low Ambient Temperature
Manual Handling / Ergonomic /  / Biological Hazards
Moving Equipment/Machinery /  / Blood Borne Pathogens / Body Fluids
Noise /  / Hygiene/Welfare
Operating / Driving MEWP’s / Legionella
Oxygen Depletion / Enrichment / Leptospirosis (Weils Disease)
Pneumatics / Hydraulics
Poor Lighting / 
Radiation
Sharp Objects /  / Chemical Hazards
Stress / Asbestos
Struck By / Against /  / Corrosive Chemicals
Trapping Points /  / Dust / Fumes
Underground Services / Harmful Chemicals
Uneven Work Surfaces / Irritant Chemicals
Use of Hand Tools / Power Tools /  / Odorous/Noxious Chemicals
Vehicles/Transport / Toxic Chemicals
Vibration

Hazard Identification, Risk Assessment & Safe Working Procedure for

Use of Reciprocating Work Shop Saw

C&P Engineering Services Ltd / Ref. 13.2.15 / Rev. 1 / 24-04-14 / Page 1 of 11

Risk Assessment

Task: - “Use of Workshop Reciprocating Saw”

The following risk assessment has been completed to ensure adequate controls are in place to eliminate or reduce the risk to as low as is reasonably practicable. In considering who may be harmed we have included C&P Maintenance employees, but for each task, depending on where it takes place, then further consideration should be given to others who may be affected by our activities e.g. Dow Corning employees and other contractors.

L = LikelihoodHR = Hazard Rating (with NO controls in place).

C = ConsequenceRR = Risk Rating (with controls in Place).

HAZARDS /

L

C

HR

/ WHO MAY BE HARMED / CONTROL MEASURES TO REDUCE THE RISK TO AS LOW AS IS REASONABLY PRACTICABLE / L / C / RR
1. Electricity - Contact with ‘live’ electrical components causing electrical shock, burns or electrocution. / 2 / 5 / 10 / C&P Workshop employees. Visitors / Only qualified and competent persons to work on electrical equipment.
All work on electrical equipment only to be carried out following isolation. C&P are competent to undertake the isolations.
For safe isolation please refer to C&P document reference 13.1.3 Safe Isolation Procedure for DEAD working on LV and ELV.
Remove plug from wall socket when not in use. / 1 / 5 / 5
2. Entanglement / 3 / 5 / 15 / C&P Workshop employees. Visitors / Reciprocating motion can cause clothing to be caught. All personnel to wear close fitting overalls while operating machine. Do not wear any jewellery, rings, ties or other items that can become entangled. Long hair MUST be placed in hair net or under close fitting cap. When supporting work piece then two hands used well away from saw blade – ensure in reach of emergency stop button. Emergency stop button fitted. / 2 / 5 / 10
3.Equipment and materials handling of unistrut pieces. Hot surface and sharp surface / 3 / 2 / 6 / C&P Workshop employees. Visitors / The unistrut materials must be clamped into vice. As they are thin metal then danger of springing and moving. Cut edges will be sharp. Machined edges also of narrow gauge and capable of laceration injuries. Wear gloves at all times when supporting or handling the material. The cut edge will become hot during the cutting process. Leather palmed gloves as a minimum when handling this area of the material or if changing saw blade directly after use. / 3 / 1 /

3

4. Poor HousekeepingSlips, Trips and Falls due to poor housekeeping. / 5 / 4 / 20 / C&P Workshop employees. Visitors / Good housekeeping practices across the workshop by the employees for a safe place of work. Painted walkways. Good safety footwear. Regular Audits by C&P supervisor and management. Audits by Dow Corning personnel. C&P standards in housekeeping, safety contacts provided and more specific training. Removal of all waste. Cleaning of saw off cuts immediately to waste bin receptacle. Cables to be positioned and secured where they will not cause a trip hazard. Where they do cross a walkway then they will be appropriately covered to reduce the chance of a trip. Take two RA for other work activities in workshop in proximity to saw cutting. / 1 / 4 / 4
5.Manual Handling – carrying and holding unistrut lengths / 5 / 3 / 15 / C&P Workshop employees. Visitors / Operators trained and competent in Manual Handling. Large and awkward sections to be handled/carried by two operatives. Gloves for protection against hot and sharp surface. / 1 / 3 / 3
6. Moving Machinery / Entanglement / Trapping pointsin Powered Machinery- includes trapping and entanglement / 3 / 5 / 15 / C&P Workshop employees. Visitors / The reciprocating saw will continue to operate until the item is cut. As operatives have to support lengths of unistrut then they place themselves closer to the moving machine. Emergency stop button fitted. No loose clothing, no loose long hair. Safe system of work attached to this RA to ensure no approach to exposed moving parts. Guard inspection and operator check. / 2 / 5 / 10
7. Noise / 2 / 3 / 6 / C&P Workshop employees. Visitors / The noise from the saw operation alone is not regarded as hazardous to health, however during the cutting of certain metal items the noise levels can increase. In this event ear defenders to be worn during time spent in these areas.Signage. / 1 / 3 / 3
8. Poor Lighting / 3 / 3 / 9 / C&P Workshop employees. Visitors / Good workshop lighting. Lighting regular maintenance / 1 / 3 / 3
9. Lone Workers- Many of the Routine Operational checks are required to be completed by one person. Lone Workers, if injured, are more likely to go undetected and could exacerbate the seriousness of the injury due to delays in rescue and treatment. / 2 / 5 / 10 / C&P Workshop employees. Visitors / Area normally occupied by more employees – area frequented by others regularly. Means of communication fixed telephone.
Never run the saw when the blade is in the raised position. Always unplug when not in use. / 1 / 5 / 5
10. Environment - waste disposal / 3 / 4 / 12 / Environment / Responsibly dispose of all generated waste by using client’s on site recycling facilities. All metal cut offs to be removed from the area and placed in the relevant waste streams. / 1 / 3 / 3
C&P Engineering Services Ltd / Ref. 13.2.15 / Rev. 1 / 24-04-14 / Page 1 of 11

Risk Matrix

First Aid Injury no disruption of activity / Minor Injury (preventing activity for one day) / Suffering (preventing activity for 3 days or longer / Major injury / Fatal
Certain / 5 / 10 / 15 / 20 / 25
Probable / 4 / 8 / 12 / 16 / 20
Likely / 3 / 6 / 9 / 12 / 15
Possible / 2 / 4 / 6 / 8 / 10
Unlikely / 1 / 2 / 3 / 4 / 5

Acceptable(1-5) No further action but ensure controls are maintained

Adequate(6-15) Look to improve at next review

Unacceptable(16-25) Stop activity and make immediate improvements

Safe Working Procedure

Final Risk Rating

The risk rating for the activity of “Use of the fixed reciprocating saw in the Workshop” has a final Risk rating of “10” if all the controls are applied at all times. Failure to implement the controls will lead to a higher risk of injury. The level of 10 is adequate (yellow section 6-15) but improvements should be made to reduce the overall risk down to acceptable (green section 1 - 5). This Risk assessment needs to be reviewed in the next 12 months (see review date).

Persons and Competency

All the C&P Engineering employees who work on this contractmust have been taken through this SWP and must sign the register to demonstrate that they understand the controls and how they are to be applied. They must be competent in the use of the saw.

PPE Requirements

The individuals on this contract are required to wear at all times:-

Safety Footwear with minimum 200Jules toe cap. The ankles must be protected.

General proban treated overalls or proban treated trousers & jacket.

General purpose leather palmed gloves or Kevlar gloves over surgical nitrile.

Safety helmet – centurion or equivalent.

Safety glasses to be worn or safety over-glasses to be worn if wearing your own prescription glasses.

High visibility waistcoat.

Plant Status

The saw will be plugged into wall socket and the electrical supply on during use..

Permits, Certificates or Registers

None

Access and Egress

Access to the C&P Workshop is controlled by C&P operatives – the unit is unlocked at the start of each shift and will be locked when not occupied. Walkways are present externally and inside the workshop, however when undertaking the task the operatives will be positioned in the work spaces inside the workshop..

Procedure

Before entering the workshop each operative must ensure they have the appropriate work shop PPE as described in the PPE section above. This will include; Safety Boots, Overalls; hard hat; eye protection; hearing protection; leather palmed gloves for handling unistrut pieces.

Each particular work project requiring unistruts will have a list of lengths of unistrut required. The number of lengths to be cut will be taken from the external storage rack and placed adjacent to the reciprocating saw but ensuring it does not cause a trip hazard for the workshop operatives. Each section will be marked and placed onto the saw table with the longest length supported by trestles. The Vice holding clamps will secure the unistrut sections.

The saw blade must be aligned on the marked line.

Inspect the condition of the plug and the mains cable since last use, if no damage then plug in the saw into the mains electricity. Check that the fixed guards are in position on the main drive and motor.

Before pressing the start button ensure the long length is held firmly down onto the trestles. NEVER leave a working saw unattended.If cutting mild steel then the oil coolant solution should be turned on and directed at the work piece cut line. The unistrut should be supported until the cut is made. The operative can alert any other work shop user of the process being undertaken.

WARNING: Never use this saw to cut wood.

Once completed the machine must be stopped. Once the blade has fully stopped then the two cut sections can be removed by gloved hand ensuring cognisance is made of the sharp and hot cut section. The discarded section, if below the minimum usable length will be discarded in the metal recycling container. The measured section will be unclamped and placed either directly onto the vehicle for distribution or will be placed on the workshop floor until the complete numbers of unistrut are cut.

The process is repeated until all the sections needed are completed.

At NO time will the operative or any other person be allowed to move to within 1m of the moving saw blade during the cutting operation.

The saw MUST be cleaned after use. This must always be achieved with the blade raised and locked and the electrical plug removed from the wall socket. Draining the coolant back to the reservoir and brushing and collecting the metal cuttings is essential for safe continued operation.

Any coolant splashes or leaks onto the workshop floor MUST be cleared up immediately. Stop the saw and determine cause of leak and then fix and clean the spillage. Absorbent granules can be used to soak up spillage.

Emergency Procedures – Telephone 3333 Internally

In the event of an emergency and depending on the site and access to such, the emergency services should be called using the internal emergency number. Raising the alarm is our first priority. All C&P employees must report to their appropriate place of safety, if the alarms are sounded. You must stay at this location and report to the Client representative. Follow the directions of the Client personnel in charge at the muster point. Lifting an eye wash station or stepping on a safety shower will raise alarm to DC Control, who will send assistance to the area accordingly.

Raising the Alarm

Telephone 3333

Use your radio – Channel 15/16 call sign “DC control”

In the event where neither of the above options are possible then use safety shower or eyewash point on plant as these will activate the alarm in DC control

Use break glass point within building for local alarm

Dow Corning Alarm Signals

Klaxon 3 seconds on 3 seconds off – Major Incident

All personnel to report to their nearest muster point indoors immediately. Swipe badge on Muster Reader.

Fire Alarm Bells

All personnel to report to their nearest fire assembly point outside immediately.

Blue Flashing Light - Outside a Building

No personnel to enter the building until advised by a DCL member.

Audible Alarm and Red Flashing Light on Process Plant

All personnel to make their work area safe and leave the area. No return until advised by a DCL Member.

Note: If the last page of this document is not attached do not worry as it does not contain any relevant information regarding the SWP. The last page is a register of signatories and is intended to be detached and returned to Gorseinon head office for filing.

“Hazard Identification, Risk Assessment & Safe Working Procedure for Use of reciprocating saw in the Workshop at Dow Corning Ltd, Barry”.

The above document has been read and explained to me by my supervisor.

I the undersigned understand the controls and how they are to be applied.

Print Name / Signature / Date

The following comments/queries were raised and discussed with my supervisor (Please insert below any concerns, comments or views which may identify additional problems):

** THIS PAGE IS TO BE SIGNED, DATED, DETACHED AND RETURNED TO GORSEINON HEAD OFFICE A.S.A.P. (VIA FAX, EMAIL, POST OR HAND) **

C&P Engineering Services Ltd / Ref. 13.2.15 / Rev. 1 / 24-04-14 / Page 1 of 11