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1 NORTH WEST AIRCONDITIONING SERVICE PTY LTD Fill = Green 204 SAFE WORK PROCEDURE Workplace/Site: Page: 1 of 8 TASK / OPERATION: Air Conditioner Maintenance Overall Risk Rating After Controls 4 Acute 3 High 2 Moderate 1 Low Personal Protective Equipment Fill = Green 204 Foot Hearing High Visibility Head Hand Protective Clothing Breathing Day Operations Normal Requirements: Safety footwear (non-slip boots), hearing protection, high visibility shirt or vest, hard hat and sun protection if required hand protection (gloves), overalls/breathing protection (if required). Safety Notes Fill = Green 204 This SWMS covers risks associated with general maintenance of air conditioning systems. Ensure the manufacturer s maintenance manual/guide is available for specific information. Main risks: from height - electrocution/electric shock exposure to harmful s (asbestos, silica, refrigerant gases, legionella bacteria etc) Authorised by Mel Milutin North West Airconditioning Service Page 1- Version 5.0
2 1. Planning Assess site. Check: - Anchor points (suitable work load and position) - Proximity to power lines - Type of roof (pitched, tile, sky lights etc) - Condition of roof (fragile, brittle etc) - Presence of hazardous materials such as asbestos, lead, silica etc) - Load bearing capacity of support walls, ceiling, roof - Height of work area - Access for equipment and materials - Number of persons expected on roof/ceiling space - Power supply - Location of existing services (heating, water, pipes, electrical leads) - Traffic Management requirements 1L Develop a site and task specific SWMS to control risks. 2. Preparation - bacteria - (legionella) - fire/explosion Ensure suitable equipment for job. Examples: - Work at heights: o Ensure scissor lift or step platforms are used. If ladders are only option, ensure they are industrial, good condition, set-up correctly and secured both top and bottom. o Where a roof pitch exceeds 35 degrees, do not stand on the roof. Work from a cherry picker, scaffold or travel restraint system. o If using travel restraint or fall arrestors, ensure harness and clips are compatible, anchor points have been assessed by qualified persons, training undertaken and emergency plan in place for rescue. Authorised by Mel Milutin North West Airconditioning Service Page 2- Version 5.0
3 2. Preparation - continued - bacteria (legionella) - fire/explosion - Manual handling o Use hand trucks, cable trolleys to move materials (such as replacement units) o Use smaller sized cable drums - Power Tools: o Guards in place o Electrical leads in good condition and tested/tagged, RCDs in use o Correct for job/used for purpose o Flame proof where required - Hazardous Materials o If cutting/drilling into structures, determine material type. Provide suitable personal protective equipment for short term works example: o Non-Friable Asbestos: Protective clothing, P1 or P2 half face (can be either disposable or cartridge) o Silica: P1 or 2 half face with particle cartridge Refrigerant Gases: Correct for type of system Cylinders labelled including weight, fill capacity, type and within test date Material safety data sheets available. Ensure correct PPE for type/quantity. Eg: Ammonia: More than 900kg impervious protective clothing with Self Contained Breathing Apparatus (SCBA) 25 mins effective life o Group B2: less than 225kg at least 1fullface respirator with appropriate cartridge Group B2: more than 225: 2 f/face respirators Quantity of any type more than 900kg: SCBA Authorised by Mel Milutin North West Airconditioning Service Page 3- Version 5.0
4 2. Preparation - continued - bacteria (legionella) - fire/explosion Ensure: - Adequate Operating and Maintenance manual available for specific system - AC system has been designed by qualified persons and meets relevant standards for design and installation - If cooling towers present evidence is obtained for previous testing/inspections including: o Biocide dosing o Regular cleaning o Monthly hetertrophic counts o Water testing o Unacceptable results have been rectified - Where in-house gas alarms/detectors are in use, seek evidence of regular testing, calibration and correct placement for type of gas (eg: both sides of compressor and downwind of machinery towards vents, high or low based on gas density to air) - Communication systems in place Note: In absence of adequate operating/maintenance manual, seek advice from suitably qualified persons to determine maintenance requirements, including: - Types of disinfectant required (for water systems) - Type of refrigerant gases - Pressure settings - Electrical settings - Flow/valves and fittings - How to isolate areas for repair works Authorised by Mel Milutin North West Airconditioning Service Page 4- Version 5.0
5 3. Pre-operational Inspection Ensure: - Traffic management in place where required - Sufficient Lighting - Suitable weather conditions - Equipment operational and in good condition - Materials available as required - Electrical leads are not placed in areas where they will pose a tripping hazard or run over. - Safety instructions for refrigerant gases available - Cylinders undamaged and caps on valves - PPE suitable condition (including harnesses, respirators, hearing protection, coveralls etc) - Gas detectors calibrated, tested and functional 4. Operation - entanglement - slips, trips - explosion Legislation breach: - Unlicensed operators Ensure: - Equipment room is clear of tripping hazards - Refrigerant pipes are insulated - Belts, pulleys, rotating shafts, fans are guarded - Electrical parts are covered - Pressure gauges are able to be read and compared to maintenance manual for required settings Isolate area for maintenance/repair. If required: - De-energize and use lock out/tag out system - If repair works include welding or other hot works: o Isolate section o Remove all refrigerant gases and purge with inert gas o Thoroughly ventilate (open doors, windows and use mechanical ventilation if required) o Ensure fire protection equipment accessible o Obtain Hot Work Permit Authorised by Mel Milutin North West Airconditioning Service Page 5- Version 5.0
6 4. Operation - continued - entanglement - slips, trips - explosion Legislation breach: - Unlicensed operators Follow task specific SMWS and maintenance manual. Ensure work areas are cleared of off-cuts/ tripping hazards regularly. Use only replacement parts as specified by manufacturer. Use pipe cutters and cable strippers rather than hacksaws and knives. Handling cylinders: - Ensure correct type - Secured (use trolleys/hand-trucks) - Do not drag, slide, roll or drop - Do not allow them to strike each other - Do not lift by valve - Do not suspend (unless manufacturer approved attachment points are provided) - Keep away from anything flammable and oxidizers When filling refrigerant gases: - Only fill to manufacturers recommendations - Fill into low pressure side of system - Disconnect service container as soon as filling is complete When discharging refrigerant gases: - Weigh container during transfer to ensure no overfill. When working in ceiling spaces: - avoid entering ceiling space work from solid platform. If required, to enter, ensure joists/purlons are capable of holding weight of person and equipment and tested for Load capacity - Don t stand on fragile areas such as plasterboard - Walk along planks and crawl if required. Authorised by Mel Milutin North West Airconditioning Service Page 6- Version 5.0
7 4. Operation - continued - entanglement - slips, trips - explosion Legislation breach: - Unlicensed operators Avoid putting face too close to work. Stand to side when tightening with pipe wrenches, strip cable away from body. Avoid working in static or awkward postures (such as bending or working with arms raised above head height) for more than 30 minutes at a time and/or 2 hours over entire shift. Ensure regular rest breaks taken. Check for refrigerant leakage from pipe connectors. Use appropriate gas detector, or soapy water in a spray bottle. If bubbles form, tighten all fittings and re-check. Check for leaks and correct pressure on completion of work. Test as required. Complete logbooks/service history etc. Only undertake work allowed under specific license. Example: - Electrician License required for electrical installations Refrigerant Mechanic with Restricted License cannot perform electrical installation work BUT they can disconnect and connect electrical equipment and replace with like components of the a/c and refrigerant equipment. Authorised by Mel Milutin North West Airconditioning Service Page 7- Version 5.0
8 5. Emergency Procedures Develop and implement an emergency response plan for the site. Include - assembly points - communication - responsible persons - emergency contacts (including nearest medical facility) - emergency rescue plan (if required) References: OHS Legislation in all States WorkSafe Victoria Prevention of falls Working on roofs 2005 WorkSafe Victoria Construction Industry Program Incident Wire Duct lifter without safety gear 2002 Health (Legionella) Regulations 2001 AS/NZS Refrigerating Systems Part 2 Safety Requirements for fixed applications To be read and signed by all employees on site: Authorised by Mel Milutin North West Airconditioning Service Page 8- Version 5.0
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