Industrial Process Chemical Line Install SWMS

Industrial chemical piping covers the installation and maintenance of pipework that conveys industrial chemicals — the pipework, fittings and connections that distribute acids, alkalis, solvents and other hazardous chemicals for industrial process systems. It is high-hazard work: the chemicals are hazardous and can cause chemical burns, toxic exposure, fire or environmental harm; the consequences of a leak or a wrong connection are severe; residual chemical can remain in the system; and the pipework materials must be compatible with the chemicals. This document is written on the basis that industrial chemical piping is carried out by competent personnel with the chemical, leak, residual-chemical and compatibility hazards rigorously controlled.

Industrial chemical piping is carried out in connection with the relevant pressure piping and process standards, with the chemicals managed as hazardous chemicals under the hazardous-chemicals provisions, the system isolated, drained, flushed and made safe before work, and the pipework materials selected for compatibility with the chemicals. The hazardous chemicals, the consequences of a leak or wrong connection, the residual chemical and the material compatibility are the defining hazards. This document coordinates the chemical, isolation, residual-chemical, compatibility and leak controls so the chemical pipework is worked on safely.

Hazards identified

9 hazards covered, sorted by priority.

Control measures

Hierarchy-of-controls order: elimination → substitution → isolation → engineering → administrative → PPE.

1. 1Administrative: manage the industrial chemicals as hazardous chemicals — obtain the safety data sheets, assess the hazards, and apply the exposure, handling and emergency controls for the specific chemicals.
2. 2Engineering: isolate, drain, flush and make safe the system before the work, confirming residual chemical is removed and the system is safe to open, because residual chemical can remain.
3. 3Engineering: select and use pipework materials and fittings compatible with the chemicals, and confirm connections are correct so chemicals are not cross-connected or conveyed in incompatible pipework.
4. 4PPE: chemical-resistant gloves, eye and face protection, protective clothing and respiratory protection appropriate to the chemicals, per the safety data sheets and AS/NZS 1715 and AS/NZS 1716.
5. 5Administrative: prevent reaction and incompatibility between chemicals, control the fire or toxic hazard for the specific chemical, and have spill and emergency arrangements in place.
6. 6Administrative: apply the confined space controls and atmospheric testing in enclosed plant spaces, and pressure test and confirm the system before it is returned to service.
7. 7Engineering: use mechanical aids for the pipework and equipment, and contain and dispose of any drained or flushed chemical correctly.
8. 8Administrative: ensure the work is carried out and certified by an appropriately licensed plumber, drainer or gasfitter under the relevant state or territory plumbing and gasfitting licensing scheme, with the relevant competencies and a compliance certificate issued where required.
9. 9Administrative: all workers must hold a valid White Card (General Construction Induction Training, CPCCWHS1001) where the work is construction work, with the plumbing, gasfitting, confined space and any other competencies required for the work.
10. 10Administrative: conduct a pre-start toolbox talk covering the day's work, identified hazards, isolations, required PPE and emergency procedures, and record attendance in the consultation section.
11. 11Administrative: consult workers and any health and safety representatives on the work and its risks, record the consultation, and keep this document available at the workplace.
12. 12PPE: eye protection to AS/NZS 1337.1, hearing protection where required, gloves appropriate to the task, high-visibility clothing, and Class I or Class II safety footwear with protective toecap to AS/NZS 2210.3.
13. 13Administrative: review and update this SWMS whenever the work scope changes, after any incident or near miss, when a worker or health and safety representative raises a concern, when new hazards are identified, or at minimum every 12 months.

Applicable Codes of Practice

Worked example

A competent process pipefitter is engaged to install and maintain pipework conveying an industrial chemical. The chemical is managed as a hazardous chemical, with the safety data sheets obtained, the hazards assessed, and the exposure, handling and emergency controls applied. The system is isolated, drained, flushed and made safe before the work, confirmed that residual chemical is removed and the system is safe to open, because residual chemical can remain. Pipework materials and fittings compatible with the chemical are selected and used, and connections confirmed correct so the chemical is not cross-connected or conveyed in incompatible pipework. Chemical-resistant gloves, eye and face protection, protective clothing and respiratory protection appropriate to the chemical are worn. Reaction and incompatibility are prevented, the fire or toxic hazard controlled, and spill and emergency arrangements in place. Confined space controls and atmospheric testing are applied in enclosed plant spaces. Drained chemical is contained and disposed of correctly. The system is pressure tested and confirmed before return to service, and the records retained.

Related legislation

• Model Work Health and Safety Act — primary duty of care; the duty to consult workers; the reckless-conduct offence; and notifiable-incident provisions, as enacted in each jurisdiction.
• Model Work Health and Safety Regulations — Section 291 high risk construction work and the SWMS preparation and review duties, and the confined space, excavation, demolition and electrical provisions where applicable, as enacted in each jurisdiction.
• The relevant plumbing and drainage standards AS/NZS 3500 (Parts 0–5), AS/NZS 5601.1:2022 for gas, the pressure piping and pressure equipment standards, the AS 4032 valve standards, and the hazardous chemicals, demolition and asbestos requirements, are called up by the relevant legislation, together with the relevant network utility, insurer and site requirements.
• Plumbing, drainage and gasfitting work is licensed under each state and territory's plumbing and gasfitting licensing scheme, with the relevant competencies for the specialist work, and compliance certification required for notifiable work; electrical work is carried out by a licensed electrician.
• Victoria operates under the Occupational Health and Safety Act 2004 and the Occupational Health and Safety Regulations 2017, with the high risk construction work, confined space, excavation and demolition provisions applying in place of the model instruments.

Frequently asked questions