Metal Fabrication Industry Safety Guide Book
Content Inside:
This guide demonstrates WorkSafe Victoria’s expectations on how to eliminate or reduce the risk of injury in the metal fabrication industry. Risk controls in this document have been implemented by industry in Victoria. The guide does not replace requirements for risk assessment and controls, with the risk of an injury varying depending on the circumstances at each workplace. To ensure a reduction in injuries, employers should review risks and develop and implement a plan for controls in consultation with Health and Safety Representatives (HSRs) and employees.
Table of Content: Introduction, The legal framework, Consultation, Information instruction and training, ‘Reasonably practicable’ control measures, How to use this guide. Manual Handling, Manual handling and musculoskeletal disorders, Unloading raw materials, Transport of materials on the shop floor (heavy), Transport of materials on the shop floor (light), Manufacturing at workstations, Die handling, Packing stillages, Loading and handling finished product. Hand tool usage: Angle grinding, Welding. Guarding: Power presses, brake presses, guillotines, environment: Plant Layout, workplace traffic management, noise, housekeeping, lighting, temperature workplace, protective clothing and equipment. Other guidance material, acknowledgments.
The practices in the red boxes should not be used in workplaces; an employer who allows these practices to be used is likely to be
in breach of OHS legislation. The solutions in the amber column are less effective in reducing risk compared to those in the green
column, and would be regularly reviewed with the aim to move towards higher order solutions (green). The solutions in the green column are the most effective at reducing risk and should be regarded as the target for all workplaces.
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MECHANICAL WORKSHOP SAFETY REGULATIONS
- Free access to the workshop areas is restricted to authorised personnel only. No other person may enter the workshop without permission.
- No machine may be used or work undertaken unless the technician-in-charge is satisfied that the person is capable of doing so safely. If equipment is fitted with guards these must be used. Equipment should never be used if the safety guards have been removed.
- Any person working in the mechanical workshop must familiarise themselves with Part 4 (Mechanical Equipment) of the University Health and Safety Policy at :- http://www.safety.ed.ac.uk/policy/part4/part4.shtm
- Any person working in the mechanical workshop must have read and signed the appropriate risk assessment if the work or equipment they are using has been risk assessed.
- Personal Protective Equipment is provided and must be used where necessary. Barrier cream, lab. coats, safety glasses/goggles and safety shoes are to be used as the work dictates. When working with machine tools or other equipment with rotating spindles, jewellery, loose clothes etc. are prohibited and long hair must be completely covered.
- No hazardous substance to health can be used before a COSHH risk assessment is undertaken and a safe system of work issued to the users.
- No person shall mount any abrasive wheel unless he/she has been trained in accordance with the Abrasive wheel Regulations 1970. Grinding machines shall only be operated by technical staff and eye protection must be worn.
- Do not carry loads such that the weight may be dangerous or vision obscured. Refer to Part Two, Section 4.7 Manual Handling of Loads of the University Health and Safety Policy at: http://www.safety.ed.ac.uk/policy/part2/part2.shtm#47
- Servicing records of all machine tools, plant and equipment must be kept. They must list the date of any service/repair and the person responsible for carrying out that service/repair. Faults which cannot be repaired immediately should be reported to David Wyse (50 4499) and a note indicating that the equipment is out of order attached to the machine where it is clearly visible.
- Report any defective equipment to the technician-in-charge.
- Smoking, eating and drinking in workshop areas is strictly prohibited.
- The gangway through the workshop must be kept clear. Any oil spillage, grease etc. must be cleaned up immediately.
- Equipment must be cleaned after use. Any materials, tools or equipment used must be tidied away.
- Precision measuring equipment, drills, etc. must be replaced in their appropriate cabinets after each working day.
- Tools and equipment must not be removed from the workshop without permission from the technician-in-charge.
- All accidents/incidents/occupational ill health must be reported by using the online reporting system at: http://www.safety.ed.ac.uk/IncidentReporting/IncidentDetails.cfm
- In the event of a fire, act in accordance with the FIRE ACTION NOTICES displayed throughout the building. Leave the building immediately and proceed to the assembly point.
- It is the responsibility of the technician-in-charge to enforce these rules.
- Problems or concerns regarding health, safety or security contact the School Safety Manager David Wyse on 50 4499.
What is the ASME?
The American Society of Mechanical Engineers (ASME) is a professional organization which promotes advances in engineering, along with professional development, education, and engineering safety. Over 120,000 people worldwide belong to this organization, which keeps members updated with publications, conferences, and other materials. Many consumers are familiar with the ASME, albeit indirectly, because the organization has created hundreds of codes and standards which are meant to increase the safety of everything from boilers to boats. A group of men founded the ASME in 1880, recognizing that mechanical engineering was playing a major role in human lives, and that this role was often deadly. In the United States alone, there were hundreds of boiler explosions every year which the men realized could be preventable, if standardized codes were used for manufacture and safety procedures. The men also wanted to promote “the art, science, and practice of mechanical and multidisciplinary engineering.” The ASME prides itself on being a diverse, innovative organization which contributes an immense amount to the field of engineering. The ASME standards are perhaps the most well known aspect of the organization. Over 600 standards are published by the ASME, and many of these standards have been adopted as legal codes in nations all over the world. The ASME also has a product safety and testing division, and extensive research labs to explore new developments in mechanical engineering. The organization’s private press produces numerous volumes and texts on mechanical engineering, and a few can be found on the bookshelf of most mechanical engineers. In addition to creating standards, the ASME also holds numerous conferences and events every year to give engineers a chance to share information with each other and discuss developments in their professional field. Professional development courses are also offered by the ASME, along with outreach to youth and college students who might be interested in mechanical engineering as a career. Expositions of professional equipment and developments in the field are also hosted by the ASME all over the world. The organization’s vision is to become “the premier organization” for mechanical engineering all over the world, and it has certainly made strides towards this goal. ASME guidelines are highly respected by engineers all over the world, as are people who are active in the organization. Millions of people since 1880 have also benefited from the ASME’s efforts to improve engineering safety and to make engineering more efficient and effective.
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Transamerica Delaval Engineering Handbook
Mcgraw-Hill, 4 Sub ed | 1983 | ISBN: 0070162506 | 620 pages | PDF | 46,1 MB
Welding Science and Technology
Chapman | 2008-03 | ISBN: 9788122420739 | 288 pages | PDF | 2,5 MB
The book completely covers the syllabus of ?Advanced Welding Technology??an elective course of UPTU, Lucknow in addition to covering a wide spectrum of other important topics of general interest to the practicing engineers and students of mechanical, production and industrial and industrial metallurgy engineering branches. Special topics like welding pipelines and piping, underwater welding , welding of plastics, welding of dissimilar metals, hardfacing and cladding have also been covered. Standard codes and practices have also been described. Numerical problems have been solved at appropriate places in the text to demonstrate the applications of the material explained.
The major goal of the present book is to provide the welding engineers and managers responsible for activities related to welding with the latest developments in the science and technology of welding and to prepare them to tackle the day-to-day problems at welding sites in a systematic, scientific and logical manner.
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Pump Characteristics and Applications,2 Ed
CRC | 2005-04-07 | ISBN: 082472755X | 568 pages | PDF | 29,8 MB
This hands-on reference offers a practical introduction to pumps and provides the tools necessary to select, size, operate, and maintain pumps properly. It highlights the interrelatedness of pump engineering from system and piping design to installation and startup. This updated second edition expands on many subjects introduced in the first edition and also provides new in-depth discussion of pump couplings, o-rings, motors, variable frequency drives, pump life-cycle cost, corrosion, and pump minimum flow. Written by an acclaimed expert in the field, Pump Characteristics and Applications, Second Edition is an invaluable day-to-day reference for mechanical, civil, chemical, industrial, design, plant, project, and systems engineers; engineering supervisors; maintenance technicians; and plant operators. It is also an excellent text for upper-level undergraduate and graduate students in departments of mechanical engineering, mechanical engineering technology, or engineering technology. About the Author Michael W. Volk, P.E., is President of Volk & Associates, Inc., Oakland, California (www.volkassociates.com), a consulting company specializing in pumps and pump systems. Volk’s services include pump training seminars; pump equipment evaluation, troubleshooting, and field testing; expert witness for pump litigation; witnessing of pump shop tests; pump market research; and acquisition and divestiture consultation and brokerage. A member of the American Society of Mechanical Engineers (ASME), and a registered professional engineer, Volk received the B.S. degree (1973) in mechanical engineering from the University of Illinois, Urbana, and the M.S. degree (1976) in mechanical engineering and the M.S. degree (1980) in management science from the University of Southern California, Los Angeles.
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The Practical Pumping Handbook
Elsevier Science | 2005-01 | ISBN:1856174107 | 384 pages | PDF | 28,5 MB
This book is a practical account of pumping, piping and seals starting with basics and providing detailed but accessible information on all aspects of the pumping process and what can go wrong with it. Written by an acknowledged expert with years of teaching experience in the practical understanding of pumps and systems.
Aids understanding of pumps to minimize failures and time-out.
A practical handbook covering the basics of the pumping process.
Written by an acknowledged expert.
Piping and Pipeline Engineering: Design, Construction, Maintenance, Integrity, and Repair
CRC | 2003-05-01 | ISBN: 0824709640 | 564 pages | PDF | 20 MB
Taking a big-picture approach, Piping and Pipeline Engineering: Design, Construction, Maintenance, Integrity, and Repair elucidates the fundamental steps to any successful piping and pipeline engineering project, whether it is routine maintenance or a new multi-million dollar project. The author explores the qualitative details, calculations, and techniques that are essential in supporting competent decisions. He pairs coverage of real world practice with the underlying technical principles in materials, design, construction, inspection, testing, and maintenance. Discover the seven essential principles that will help establish a balance between production, cost, safety, and integrity of piping systems and pipelines The book includes coverage of codes and standards, design analysis, welding and inspection, corrosion mechanisms, fitness-for-service and failure analysis, and an overview of valve selection and application. It features the technical basis of piping and pipeline code design rules for normal operating conditions and occasional loads and addresses the fundamental principles of materials, design, fabrication, testing and corrosion, and their effect on system integrity.
Table of Contents
Preface Ch. 1 Codes, Standards and Practice 1 Ch. 2 Fundamentals 34 Ch. 3 Materials 42 Ch. 4 Internal Pressure 81 Ch. 5 External Pressure 121 Ch. 6 Layout and Supports 126 Ch. 7 Flexibility and Fatigue 152 Ch. 8 Vibration 186 Ch. 9 Fluid Transients 216 Ch. 10 Wind Design 241 Ch. 11 Seismic Design and Retrofit 246 Ch. 12 Explosions 271 Ch. 13 Subsea Pipelines 287 Ch. 14 Buried Pipe 302 Ch. 15 Welding 311 Ch. 16 Examination 329 Ch. 17 Pipe Flange 349 Ch. 18 Mechanical Joints 377 Ch. 19 Leak and Pressure Test 382 Ch. 20 Degradation in Service 396 Ch. 21 Fitness-for-Service 419 Ch. 22 Maintenance, Reliability and Failure Analysis 446 Ch. 23 Repair Techniques 471 Ch. 24 Plastic Pipe 492 Ch. 25 Valves 505 App Standard Pipe Sizes 526 Index 533
Fabrication and Welding Engineering
Newnes | 2008-07-14 | ISBN: 0750666919 | 592 pages | PDF | 8,1 MB
This brand new textbook by one of the leading engineering authors covers basic sheet-metal fabrication and welding engineering principles and applications in one volume – an unrivalled comprehensive coverage that reflects current working and teaching practice. It is fully up-to-date with the latest technical information and best practice and also includes chapters on non-technical but equally essential subjects such as health and safety, personal development and communication of technical information.
Roger Timings covers these areas of mechanical engineering and workshop practice in a highly practical and accessible style. Hundreds of illustrations demonstrate the practical application of the procedures described. The text includes worked examples for calculations and key points to aid revision. Each chapter starts with learning outcome summaries and ends with exercises which can be set as assignemnts.
The coverage is based on the SEMTA National Occupational Standards which makes this book applicable to a wide range of courses and ensures it also acts as a vital ongoing reference source in day-to-day working practice. All students, trainees and apprentices at up to and including Level 3 will find this book essential reading, particularly those taking:
Level 2 NVQs in Performing Engineering Operations
Level 2 and 3 NVQs in Fabrication and Welding Engineering
Level 2 NVQs in Mechanical Manufacturing Engineering
C&G 2800 Certificate and Level 3 Diplomas in Engineering and Technology
SEMTA Apprenticeships in Engineering
* Welding&Fabrication topics presented together in one text, in line with current teaching practice
* Fully up to date with the latest specifications for fabrication & welding course units for all the most popular qualifications
* Written by a leading engineering author
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Welding Guide
Publisher: Woodhead | Pages: 320 | 2006-04-30 | ISBN 185573947X | PDF | 2 MB
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New developments in advanced welding
CRC; 1 edition | October 11, 2005 | ISBN: 0849334691 | 298 pages | PDF | 6 Mb
New Developments in Advanced Welding presents some of the most significant developments in welding technology and explores their applications in mechanical and structural engineering. This book reviews advances in gas metal arc welding, tubular cored wire welding, and gas tungsten arc welding. It discusses developments in laser welding, including laser beam welding and Nd:YAG laser welding. The text also analyzes other new techniques such as electron beam welding, explosion welding, and ultrasonic welding. It concludes with a review of current research as well as health and safety issues. Written by international experts, this will be a standard reference for the entire welding community.
Theory of Thermomechanical Processes in Welding
Springer; 1 edition | July 30, 2005 | ISBN: 140202990X | 174 pages | PDF | 1.1 Mb
This book presents a modern viewpoint of welding thermomechanics and provides a unified and systematic continuum approach for engineers and applied physicists working on the modelling of welding processes. The theory presented includes developments in the areas of welding thermodynamics, thermoplasticity and numerical methods. The book describes the calculation of thermal stresses in welding structures, the theory of heat conduction in welding, and the basic equations of thermoplasticity, then applies the concepts to solutions of thermoplasticity problems and to thermal stresses in arc welding, laser welding, spot welding, electroslag welding and friction welding.
Publisher: CRC | Pages: 231 | August 2, 2007 | ISBN 1420063375 | PDF | 3 MB
Computational Welding Mechanics (CWM) provides an important technique for modeling welding processes. Welding simulations are a key tool in improving the design and control of welding processes and the performance of welded components or structures. CWM can be used to model phenomena such as heat generation, thermal stresses, and large plastic deformations of components or structures. It also has a wider application in modeling thermomechanical and microstructural phenomena in metals. This important book reviews the principles, methods, and applications of CWM.
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