Pipeline Welding — Safe Work Method Statement
Safe Work Method Statement for field welding of steel pipelines, including stringing and pipe handling with sidebooms or excavators, line-up and fit-up, preheating, manual and semi-automatic welding, welding in bellholes and trenches, coating and inspection.
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Pipeline welding for gas, oil, water and slurry lines combines heavy pipe handling, welding in the open and in trenches, and in some cases work on or next to pipelines that are already carrying product. It is High Risk Construction Work because powered mobile plant (sidebooms, excavators and welding tractors) is moving throughout the right of way, and because tie-ins and repairs are often done in a bellhole or trench deeper than 1.5 metres. Work on or adjacent to pressurised gas mains or in an area that may have a flammable atmosphere is also HRCW. A SWMS is required.
The biggest pipeline welding hazards are not the arc. They are being crushed by a suspended or rolling pipe, being caught between pipe and plant during line-up, trench collapse during tie-ins, and fire or explosion when welding near pipe that has contained hydrocarbons. Pipe must be skidded and chocked so it cannot roll, and nobody should stand under a suspended joint or between pipe and the trench wall. Hot tapping and welding on live pipelines is specialist work and needs a separate procedure approved by the pipeline owner.
Welding hazards still matter. Cellulosic electrodes used for downhill pipe welding produce heavy fume. Welding generators in wet ground increase shock risk, and preheating with gas torches or induction adds burn and fire risks. Radiographic inspection of welds uses ionising radiation, so it must be done by licensed radiographers with exclusion zones set under the requirements of your state or territory radiation regulator.
Welders must be qualified to the welding procedure for the pipeline. AS 2885 covers the design, construction and welding of gas and liquid petroleum pipelines, and the pipeline owner will specify the welding procedures and inspection requirements. Plant operators must be competent, and some plant or lifting tasks may need a licence. Check your state or territory regulator. Long days in the sun on the right of way make heat stress a real risk.
Customise this template with the pipeline owner and pipe specification, the welding procedure and process, the plant used for pipe handling and its rated capacity, the trench or bellhole depth and support method, whether the work is near or on a live line, the gas testing requirements, the radiography contractor and exclusion zone, the hot work permit reference, and the fire and heat stress controls.
Personal Protective Equipment
High Risk Construction Work Types
- •Work in or near a shaft or trench deeper than 1.5 metres, or a tunnel
- •Work on or near pressurised gas distribution mains or piping
- •Work in an area that may have a contaminated or flammable atmosphere
- •Work in an area with movement of powered mobile plant
Risk Assessment
1.Stringing and pipe handling
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Crushed by suspended pipe or rolling pipe | Catastrophic | Lift pipe with plant rated for the load at radius, using rated pipe hooks, vacuum lifters or slings. Nobody under a suspended pipe. Tag lines to control pipe. Pipe placed on skids and chocked so it cannot roll. Never stand on the downhill side of pipe on a slope. | Low | Plant Operator / Pipe Crew |
| Sideboom or excavator overturns | High | Work within the machine's load chart. Keep plant on stable ground away from trench edges. Counterweight extended on sidebooms when lifting. | Low | Plant Operator |
2.Line-up and fit-up
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Hands or body caught between pipe ends or pipe and plant | High | Use internal or external line-up clamps. One person directs the plant operator using agreed signals. Hands kept out of the gap during final positioning. | Low | Line-up Crew |
| Cuts and eye injuries from bevelling and grinding | Moderate | Guard on grinder, correct disc for speed and task. Face shield over safety glasses. Spark direction away from others. | Low | Welder / Grinder Operator |
3.Preheating
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Burns and fire from preheat torches or induction coils | Moderate | Inspect torch hoses and fittings before use. Flashback arrestors fitted. Clear dry grass and combustibles around the joint. Mark hot pipe. Induction equipment installed and maintained by competent persons. | Low | Welder / Helper |
4.Welding on the right of way
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Electric shock from welding circuit in wet conditions | High | Generator earthed per manufacturer. Leads and electrode holders in good condition. Dry gloves. Use a voltage reduction device where fitted. Stand on dry boards or mats in wet ground. Stop welding in rain where insulation can't be maintained. | Low | Welder |
| Fume from cellulosic or low-hydrogen electrodes | High | Position upwind of the arc. Use a respirator with fume rating or PAPR when welding in bellholes, shelters or still air. Review electrode SDS. | Moderate | Welder |
| Arc flash to welders and nearby workers | Moderate | Welding helmet with correct shade. Welding screens or shelters where others are close by. Helpers wear tinted glasses. | Low | Welder / Helper |
| Grass or bushfire started by sparks | High | Clear vegetation around welding points. Fire extinguishers and water on each welding rig. Check fire danger rating and total fire ban days and comply with permit conditions. | Low | Supervisor |
5.Tie-ins in bellholes and trenches
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Trench or bellhole collapse | Catastrophic | Bellholes deeper than 1.5 m shored, shielded or battered to suit ground. Spoil at least 1 m from edge. Ladder access. Competent person inspects before each entry. | Low | Supervisor / Competent Person |
| Fire or explosion near a pipe that contains or has contained product | Catastrophic | Gas test before and continuously during hot work near any existing pipeline. Isolation, purging and gas-free certificate as required by the pipeline owner. Hot tapping only under the owner's approved procedure. | Moderate | Supervisor / Pipeline Owner Representative |
6.Radiography and inspection
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Ionising radiation exposure | High | Radiography done only by licensed radiographers. Exclusion zone set and barricaded by the radiographer. All crew clear before exposure. Radiography schedule communicated at the daily pre-start. | Low | Radiographer / Supervisor |
7.Coating and pack-up
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Chemical exposure from field joint coatings | Moderate | Follow SDS for coating products. Gloves and eye protection. Ventilation for solvent-based products. | Low | Coating Crew |
| Heat stress during long shifts | High | Shade, cool drinking water, scheduled breaks and buddy checks. Adjust work times on very hot days. | Moderate | Supervisor |
Relevant Codes of Practice
Worker Acknowledgement
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