Product Overview

Summary: This procedure sets out a clear, step-by-step system for safely inspecting, operating and maintaining cooling systems used in metal production environments. It helps prevent equipment failures, burns, leaks and environmental releases while supporting compliance with Australian WHS and environmental obligations.

Cooling systems in metal production facilities operate under extreme thermal and mechanical loads, often in close proximity to molten metal, high-pressure fluids and energised equipment. When these systems are not maintained in a controlled and documented way, the consequences can include sudden line shutdowns, equipment damage, worker exposure to hot surfaces or steam, and uncontrolled releases of cooling water or chemicals. This Safe Operating Procedure provides a structured, WHS-aligned approach to cooling system maintenance, integrating safety, reliability and environmental controls into one practical document.

The SOP guides workers through planning and isolating systems, verifying lockout/tagout, managing residual energy, and performing inspections, cleaning, testing and recommissioning of cooling circuits, pumps, heat exchangers, cooling towers and associated control equipment. It clarifies who does what, when, and to what standard, reducing ambiguity and variation between shifts and contractors. By implementing this SOP, metal production businesses can significantly reduce unplanned downtime, extend asset life, and demonstrate due diligence under Australian WHS law and relevant environmental regulations, while giving workers clear instructions for working safely around hot surfaces, pressurised fluids and chemical treatment systems.

Key Benefits

• Reduce unplanned downtime and production losses by standardising preventative maintenance on critical cooling assets.
• Ensure worker safety when working around hot surfaces, steam, high-pressure lines and energised equipment through clear isolation and verification steps.
• Improve compliance with Australian WHS and environmental requirements by documenting safe handling of cooling water, chemicals and blowdown discharges.
• Extend the life of pumps, heat exchangers, cooling towers and pipework by controlling scale, corrosion and fouling through consistent inspection and treatment practices.
• Streamline contractor and new-employee onboarding with a clear, auditable procedure for cooling system maintenance tasks.

Who is this for?

• Plant Managers
• Production Supervisors
• Maintenance Planners
• Mechanical Fitters
• Industrial Electricians
• WHS Managers and Advisors
• Process Engineers
• Reliability Engineers
• Operations Managers
• Shift Team Leaders

Hazards Addressed

• Contact with hot surfaces, steam and heated fluids during maintenance activities
• Exposure to high-pressure water, hydraulic fluids or refrigerants from leaks or line failures
• Uncontrolled release of cooling water or chemical treatment solutions
• Electrical hazards associated with pumps, fans, control panels and instrumentation
• Slips, trips and falls around wet, algae-affected or corroded access areas near cooling systems
• Chemical exposure from biocides, corrosion inhibitors, anti-scalants and water treatment chemicals
• Confined space risks in cooling towers, sumps, pits and large tanks where applicable
• Manual handling injuries from lifting motors, pumps, filters, strainers and pipe sections
• Legionella and other biological hazards in poorly maintained cooling towers
• Burns or eye injuries from pressurised line failures or sudden venting of hot fluids

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and System Description
• 3.0 Roles, Responsibilities and Competency Requirements
• 4.0 Applicable Legislation, Standards and Codes of Practice
• 5.0 Cooling System Components and Interfaces with Metal Production Processes
• 6.0 Hazard Identification and Risk Controls
• 7.0 Required PPE, Tools and Test Equipment
• 8.0 Pre-Maintenance Planning and Permit Requirements
• 9.0 Lockout/Tagout and Isolation Procedures for Cooling Systems
• 10.0 Depressurisation, Draining and Residual Energy Management
• 11.0 Routine Inspection and Preventive Maintenance Tasks
• 12.0 Cleaning, Descaling and Flushing of Cooling Circuits
• 13.0 Maintenance of Cooling Towers, Heat Exchangers and Pumps
• 14.0 Chemical Handling and Water Treatment Management
• 15.0 Reassembly, Re-pressurisation and Leak Testing
• 16.0 System Start-up, Commissioning and Operational Checks
• 17.0 Legionella and Microbial Risk Management (where applicable)
• 18.0 Environmental Controls and Waste/Blowdown Management
• 19.0 Emergency Procedures for Leaks, Line Failures and Overheating Events
• 20.0 Documentation, Maintenance Records and Reporting
• 21.0 Training, Induction and Competency Verification
• 22.0 Review, Audit and Continuous Improvement of the Procedure

Legislation & References

• Work Health and Safety Act 2011 (Cth) and relevant state and territory WHS Acts
• Work Health and Safety Regulations 2011 (Cth) and equivalent state and territory regulations
• Safe Work Australia – Code of Practice: Managing the Work Environment and Facilities
• Safe Work Australia – Code of Practice: Managing Risks of Hazardous Chemicals in the Workplace
• Safe Work Australia – Code of Practice: Confined Spaces
• Safe Work Australia – Code of Practice: Managing Noise and Preventing Hearing Loss at Work (where cooling fans and pumps generate high noise levels)
• AS/NZS 4024 series: Safety of machinery
• AS/NZS 3000: Electrical installations (Wiring Rules)
• AS 3666 series: Air-handling and water systems of buildings – Microbial control (for cooling towers and similar systems)
• AS/NZS 4801: Occupational health and safety management systems (superseded but still commonly referenced in industry)
• Environment Protection Authority (EPA) guidelines applicable in the relevant state or territory for cooling water discharge and blowdown