Risk Control Worksheet

ASSESSMENT DETAILS

Campus: Clayton Faculty: Engineering

Department: Materials Engineering Building/Room: 37/186, 177,182

Other:

Assessment Date:

Area/ Task/ Process Description: Prac T9 – Precipitation hardening

Assessment Team:
Name Signature
Julian Rosalie (Demonstrator)

HOW TO USE THIS WORKSHEET
1. Review the identification section of each of 5 major hazard categories on the Risk Control Reference Sheets. Identify the
relevant hazards noting the Hazard Code and briefly and separately describing each hazard associated with the work,
equipment, process or work practice. (Description of Hazard)
2. Use the appropriate matrix to assess
3. The possible outcome presented by each hazard (Consequence)
4. The possibility of that outcome occurring (Likelihood)
5. Cross reference the consequence and likelihood to determine the risk (Risk)
6. Outline the preventative/corrective action (Corrective Actions/Risk Controls)
7. Provide a realistic date by which the actions should be completed/implemented (Timing)
8. Nominate the person responsible for the follow of the actions (Responsibility)

CORRECTIVE ACTION PLANNING & REVIEW
1HIERARCHY OF
CONTROLS

For each of the identified hazards that are assessed as an extreme, high or
medium risk a corrective action / continuous improvement plan should be
developed and reviewed as required.

When developing corrective action or control strategies the HIERARCHY OF
CONTROLS should be considered. The single most important outcome of a risk 1.Elimination / Substitution
assessment is to implement effective and sustainable controls to prevent or
significantly reduce the chance of injury, illness or exposure. 2.Engineering Controls

4 levels of controls define the hierarchy. The top two levels Elimination/ 3.Training and procedures

4.Personal Protective Equipment

equipment H4 etc.Replace the H7 spatter or may result in superheated steam being lid of the salt bath soon after placing the samples violently expelled from the bath. Wear heat resistant into the salt baths and this may cause salt to gloves. are more difficult to defeat and require much less continuing human effort than the lower level controls. As corrective actions are planned every effort should be made to implement the top 2 levels of control. Make slipping hazard. before use to detect any damage C4 Timing immediate Responsibility Technician in charge High temperatures of samples being removed and Wear heat resistant gloves and take care with then quenched removal of samples to prevent any entanglements E9 Consequence Likelihood D4 Risk low with other samples and place the quenching M5 water bucket within easy reach Timing immediate Responsibility operator Contact with the salt baths and lids when placing Wear lab coats and thermal resistance gloves. Safety C1 precautions wear gloves and safety glasses when Consequence Likelihood L5 Risk low in contact with the salt either in solid state or C2 liquid state Timing immediate Responsibility operator October 2002 . It is irritating to the eye so wash with water and contact doctor. Heat Treatment Salt Baths 1Description of Hazard Hazard Corrective Actions/ Risk Controls No. Contact doctor or poisons information Temposal used R8/R36/R25/S46 Hazard Group C centre if swallowed. specimens safety glasses H7 Consequence Likelihood L3 Risk medium Timing immediate Responsibility operator C5 Salt spills or water spills on the floor may cause a Spills should be cleaned up immediately. Visually inspect the leads. This is likely to occur during sure quenching bucket is not full so water will taking samples out and putting into quenching not drip during movement of the bucket. Consequence Likelihood L5 Risk Medium Timing immediate Responsibility operator C3 Electrical hazards associated with use of 240V Ensure that earth leakage protection or residual electrical equipment current devices are fitted to all general power Consequence Likelihood L5 Risk low circuits. Substitution and Engineering Controls are by far the most effective in preventing or reducing risks because they rely much less on human behavior. The temperature of the salt baths can be up to Wear heat resistant gloves and safety glasses 600oC and thus the hot salt can spatter when when taking samples out or putting samples into H7 putting samples in or taking them out the baths Consequence Likelihood L4 Risk Medium Timing immediate Responsibility operator C3 Water that may be on the samples that were Make sure that the samples are properly dried quenched or cleaned prior to putting the samples and do not contain any water. occurs. Make H2 water bath sure the quenching water bucket is close to the bath Consequence Likelihood L5 Risk medium C2 Timing immediate Responsibility operator Salts used in the salt bath can come into the Wash with large amount of water if skin contact contact of person. face shield and safety glasses.

materials or powdered metals Responsibility Temposal used R8/R36/R25/S46 Hazard Group C Timing immediate Technician in charge H9 Consequence Likelihood L5 Risk medium C2 The salts will decompose to produce NO2 if Make sure the salt baths operate in the involved in a fire (Temposal) i temperature range specified for the salt in use and prevent overheating of the baths by accurate C2 Consequence Likelihood L3 Risk low temperature control devices C3 Timing immediate Responsibility Technician in charge October 2002 . Salts are ignitable if stored with combustible Make sure salts are stored away from materials or comes into contact with flammable combustible materials.

before use H4 to detect any damage Consequence C4 Likelihood L5 Risk low Timing Responsibility Technician in charge High temperatures of samples being removed and then Wear heat resistant gloves and take care with removal quenched of samples to prevent any entanglements with other samples and place the quenching water bucket within E9 easy reach Consequence Likelihood D4 Risk low M5 Timing Responsibility operator Contact with the oil baths and lids when placing Wear lab coats and thermal resistance gloves specimens H7 Timing Responsibility operato Consequence C5 Likelihood L3 Risk medium Oil spills or water spills on the floor may cause a Oil and water spills should be cleaned up immediately. This is likely to occur during taking Make sure quenching bucket is not full so water will samples out and putting into quenching water bath not drip during movement of the bucket. Visually inspect the leads. slipping hazard. There is a risk of hot oil spattering when when taking samples out or putting samples into putting samples in or taking them out the oil baths Consequence C3 Likelihood L4 Risk Medium Immediate Operator Samples may still be wet following water quenching. Make sure that the samples are properly dried and do Moisture contacting hot oil will generate superheated not contain any water. face steam and by splatter molten salt over large distances. Make sure H2 the quenching water bucket is close to the oil bath Consequence C2 Likelihood L5 Risk medium Timing Responsibility October 2002 . shield and safety glasses. Replace the lid of the oil bath soon after placing the Consequence C3 Likelihood L5 Risk Medium H7 samples Timing Responsibility operator Electrical hazards associated with use of 240V Ensure that earth leakage protection or residual electrical equipment current devices are fitted to all general power circuits. Wear heat resistant gloves. The temperature of the oil baths can be up to Wear heat resistant gloves and safety glasses H7 200oC.Oil baths 2Description of Hazard Hazard Corrective Actions/ Risk Controls No. equipment etc.

H1 Crushing hand during set-up No change to existing controls. Likelihood. or wear safety compression tests or broken parts may fly out glasses. the wearing of steel capped safety shoes should be considered. Responsibility. Use caution when loading samples. Risk. October 2002 . C3 L5 Medium Immediate Demonstrator (to check suitablility of shoes and to supervise) Student (to use caution and be properly attired) Test piece may be ejected from platens during Safety shield should be closed during test. Responsibility. Risk. Demonstrator to supervise set-up and sample change-over. Ensure that there is no tension in the test piece before removing. Likelihood. Risk. Timing. unexpectedly. Timing. Likelihood. Consequence. Responsibility. Consequence. Set crosshead limit switches carefully before loading samples. Timing. Responsibility. Likelihood. Consequence. Responsibility. Timing. especially when removing strained but intact samples. Risk. Consequence. C2 L5 Medium Immediate Demonstrator (to supervise) Student (to use caution) H2 Dropping load cells or other fittings on feet during Closed shoes should be always be worn when operating the test set up. Likelihood. C3 L4 Medium Immediate Demonstrator (to supervise) Student (to use PPE) Consequence. Likelihood. Risk. Consequence. Machine is to be operated by SPME trained staff only. Likelihood. Risk. Timing. When handling load cells or heavy grips.Tensile Testing – Hounsfield 3 Hazard 4Description of Hazard Corrective Actions/ Risk Controls No. Risk. Keep other staff away from computer when loading sample to avoid unexpected operation. Responsibility. Consequence. Safety glasses to be worn. machine. Timing. Responsibility. Timing.

Likelihood. Check leads for damage or fault before operating Consequence. Responsibility. Timing. Likelihood. Hardness testing 5 Hazard 6Description of Hazard Corrective Actions/ Risk Controls No. M4 D5 Low Immediate Student H4 Electrical hazard associate with mains voltage Ensure that Earth Leakage Protection or Residual Current equipment Devices are fitted to all general power circuits used.50 minutes work then 10 minute break) Move and stretch Consequence. Risk. Responsibility. Likelihood. Risk. M4 D4 Low Immediate Student October 2002 . Use portable devices if fixed ones are not installed. C4 L5 Low Immediate Student E2 Sustained awkward posture Operator to take a 10 minute break per hour operating machine (i.e.e. Timing. Rest eyes during break Consequence. E6 Risk of eyestrain resulting after prolonged periods of Ensure lab is adequately lit while working work Operator to take a 10 minute break per hour operating machine (i. Timing. Risk.50 minutes work then 10 minute break). Responsibility.

Decanting to be performed within a fume cupboard with sash lowered so as to protect the face.5)oC when mixing Winchester of acid is to be kept sealed when outside the fume (Low volatility). cupboard. Winchester to be carried either with two hands around Methanol at room temperature when body of vessel or in a safety container. perchloric/methanol solutions. methanol solution. decant and mix in fume body of vessel or in a safety container. PPE to be worn – long high grade PVC gloves. C3 d. Up to 0. decanting.5 C. Previous flow tst to be within the last 12 months and at -25(+/. C2 d. Safety shower and eye wash available within lab Consequence. apron. in a fume B. L5 Medium Technician C1 Risk of burns to skin from perchloric Solution to be prepared by lab staff – students and demonstrator acid during preparation of perchloric / thus isolated from inhalation risk during preparation. Hazard Group E R45 (Low risk of inhalation) Consequence. (Medium volatility).5L cupboard. Hazard Corrective Actions/ Risk Controls C1 Inhalation of perchloric acid fume Solution to be prepared by lab staff – students and demonstrator during preparation of thus isolated from inhalation risk during preparation. Timing. Winchester immediately returned to the storage cabinet after decanting. Sash height to be lowered to at least the height indicated o at room temperature when decanting by horizontal line. Winchester to be carried either with two hands around when in use). R23/25 (Low lowered Risk of inhalation) Winchester immediately returned to the storage cabinet after o Methanol boiling point =64. solution. of perchloric acid = 198 C. Winchester immediately returned to storage cabinet after Winchester of acid (Lowv olatility decanting. face shield. Likelihoo Risk. Perchloric acid only to be opened. (Inhalation potential unlikely). Likelihoo Risk. Responsibility. Decanting to be performed within a fume cupboard with sash Hazard group C – R11. decant and mix in fume cupboard (Inhalation potential highly unlikely) October 2002 . Acid cupboard. enclosed shoes. long sleeves and long trousers. Timing. decanted etc.5L Winchester of Methanol (High volatility during use).P. Low Immediate Technician L4 C1 Inhalation of methanol fumes during Solution to be prepared by technician– students and demonstrator preparation of perchloric/methanol thus isolated from inhalation risk during preparation. Winchester to be carried either with two hands around body of vessel or in a safety container.7Electropolishing 8Preparation 9Description of Hazard No. Immediate Responsibility.upto 2. decanting and at -25(+/-5)oC when mixing. plastic Hazard group E – R45.

Timing. Timing. Ensure that the solution temperature does not rise above 35oC during storage Consequence. Substitute methanol for ethanol in cooling and rinsing operations. C4 d. Ensure that there are no sources of ignition. PPE to be worn – long high grade PVC gloves. perchloric acid to be added slowly to methanol (never vice versa) while monitoring the temperature of the methanol. Consequence. Ensure that there are no sources of ignition. Consequence. Low C5 October 2002 . Low Immediate Technician L5 H7 Exothermic reaction during mixing of Solution to be prepared by technician– students and demonstrator perchloric acid and methanol which thus isolated from inhalation risk during preparation. face shield. 4 d. long sleeves and long trousers. spartks or flame in or in the vicinity of the fume cupboard during mixing. Responsibility. cabinet away from incompatible substances and light. which procedures were not followed. A solution was left tightly capped in direct sunlight and not collected and Store prepared solution in a glass Winchester in a ventilated appropriately stored. enclosed shoes. Low Immediate Technician L5 H7 Possible explosion of Winchester Winchesters containing perchloric/methanol mixtures are to be following decanting of the solution loosely capped and not tightly sealed. C2 d. Substitute methanol for ethanol in cooling and rinsing operations. Likelihoo Risk.C Likelihoo Risk. Responsibility. Responsibility. has the potential to boil solution with attendant risk of fire. sparks or flame in the close to the storage area. Methanol to be cooled to -25(+/-5)oC by immersing beaker in methanol cooled with liquid nitrogen before addition of acid. Tae particular care to ensure the solution temperature does not rise above the flashpoint for methanol (11oC) during mixing. heat. Minimise possible contamination of the soltution by triple washing One incident recorded in Sep 2000 in Winchesters and equipment with clean fresh water before use. Decanting to be performed within a fume cupboard with sash lowered so as to protect the face. Minimise possible contamination of the soltution by triple washing Winchesters and equipment with clean fresh water before use. heat. Maintain the temperature of the methanol at -25(+/-5)oC during mixing. Timing. due to evolution of gas from solution. Likelihoo Risk. plastic apron.

Minimise possible contamination of the soltution by triple washing Winchesters and equipment with clean fresh water before use. enclosed shoes. Winchester to be carried either with two hands around body of vessel or in a safety container. Risk. Medium Timing. Winchester immediately returned to storage cabinet after decanting. Ensure that the solution temperature does not rise above 35oC during storage Consequence. be loosely capped and not tightly sealed. Risk.36. C3 Technician C1 Risk of burns to skin from perchloric acid during PPE to be worn – safety glasses. Acid at room two hands around body of vessel or in a safety container. Safety shower and eye wash available within lab Consequence. Hazard group E – 23. of perchloric acid = 198 C.R26. C4 C5 Low Immediate Demonstrator October 2002 . decant and mix in fume cupboard. Substitute methanol for ethanol in cooling and rinsing operations. Responsibility. L5 Risk. Hazard Group E – R23. Up to 2.5L Winchester of acid (Lowvolatility when in use). lab coat. students during set-up thus minimized. long sleeves and handling and use of perchloric / methanol solution. Likelihood.45 Winchester immediately returned to the storage cabinet after pouring. temperature when decanting and at -25(+/. Store prepared solution in a glass Winchester in a ventilated cabinet away from incompatible substances and light. C2 L4 Low Immediate Technician H7 Possible explosion of Winchester following decanting Winchesters containing perchloric/methanol mixtures are to of the solution due to evolution of gas from solution. (Inhalation potential unlikely). R36.Handling and use Hazard 10Description of Hazard No. Winchester to be carried either with o B. Corrective Actions/ Risk Controls C1 Inhalation of perchloric acid fume during Solution to be handled by researcher– inhalation risk to electropolishing. Consequence. Timing. Responsibility. Ensure that there are no sources of ignition. Timing. Immediate Responsibility. heat.P. sparks or flame in the close to the storage area.25. Likelihood. Likelihood.5)oC when mixing (Low volatility). R45 (Low risk of Winchester of acid is to be kept sealed when outside the inhalation) storage cabinet. long trousers.

fume cupboard at any one time. Risk. evolving gases. Consequence. Likelihood. for the evolution of gases and buildup of pressure. Timing. Substitute methanol for ethanol previously used in cooling and rinsing operation. replacing the winchesters of electropolishing solution Winchester to be held with two hands on the body of the from the dedicated storage cabinet. vessel or in a safe storage container. supervisor. Timing. Risk. Ensure that there are no sources of ignition. Responsibility. Risk.H7 Possible explosion or fire resulting from the use of Minimise quantities of electropolishing solution (1. due to evolution of gases and / or times. etc. Only one type of electropolishing solution within the esters from the solution. NO reported instances of such manual handling injuries within SPME Consequence. Minor (C4) Highly unlikely Low Immediate Operator. Immediately dispose of solutions that are discoloured. technician (L5) E2 Manual handling hazard associated with removing ad Care with transport. Minimise possible contamination of solution by triple washing equipment with clean fresh water followed by single washing with rinsing methanol prior to use. each user to use only their own electrolpolishing solution. Visually inspect solution for discolouration. evolution of gase. on a weekly basis and before and during decanting of solution. Immediately return Winchesters of solution and methanol to their respective storage cabinets following decanting. Timing. etc. Responsibility. heat.5L max) perchloric acid / methanol solutions or methanol during and methanol (3L max) within the fume cupboard at a ll the polishing process. etc. Use portable devices if fixed ones are not installed. each electrolpolishing solution to be used with one type of alloy only. after prac cycle is complete or immediately upon discolouration. Dispose of solutions agter one month. M4 D5 Low Immediate Technician 11 October 2002 . sparks or flame in or around the storage cupboard and working area. Check leads for damage or fault before operating Consequence. Responsibility. C2 L5 Medium Immediate Technician H4 Electrical hazard associate with mains voltage Ensure that Earth Leakage Protection or Residual Current equipment Devices are fitted to all general power circuits used. No reported incidences of fire or explosion during Do not seal Winchester lids – leave loosely capped to allow electropolishing operations. Likelihood. Likelihood.

room ventilation (inhalation discoloured. Immediately dispose of solutions that are volatility during use). sealed.36.5oC. C3 L2 Medium October 2002 . Responsibility. Consequence. evolving gases.26. potential Likely) Hazard Group E – R23. etc. Risk. Likelihood.Storage 12Description of Hazard Hazar Corrective Actions/ Risk Controls d No. on a weekly basis and before and during decanting in cupboard but with caps on loosely (assume medium of solution. etc. evolution of temperature (Medium volatility). etc. solution at room Visually inspect solution for discolouration. All spills to be dealt with immediately. after prac cycle is complete or immediately upon discolouration. up to 25L of solutions gase.45 Dispose of solutions after one month. C1 Inhalation of fumes from the perchloric acid / methanol Winchesters to be kept loosely capped rather than tightly solutions whilst stored in the etchants cupboard. Timing. Solution boiling point > 64.

sparks or flame in or around the storage cupboard and working area. Maintain the temperature of solutions below 35oC at all times – not that toom 186 has 24 hour air conditioning. Risk. evolving gases. evolution of gase. on a weekly basis and before and during decanting of solution. Ensure that there are no sources of ignition. heat. Likelihood. Immediately dispose of solutions that are discoloured. Responsibility. etc. each electrolpolishing solution to be used with one type of alloy only. etc. due to evolution of max 25L. Minimise possible contamination of solution during use by triple washing equipment with clean fresh water followed by single washing with rinsing methanol prior to use. Consequence. Provide supervisors and users with documented safe work procedures. Users are not to be licensed to use electropolishing solutions until they have completed safety induction. Substitute methanol for ethanol previously used in cooling and rinsing operation. Minimise possible contamination of solution during preparation by triple washing equipment with clean fresh water prior to use. provide adequate supervision to users. Winchesters to be kept loosely capped rather than tightly sealed. each user to use only their own electrolpolishing solution.H7 Possible expolosion or fire during the storage of Minimise quantity of electropolishing solutions in cupboard – perchloric acid / methanol solutions. etc. Visually inspect solution for discolouration. Substitute methanol for ethanol previously used in cooling and rinsing operation. gas and / or esters from the solution. after prac cycle is complete or immediately upon discolouration. Store solutions in glass Winchesters away from incompatible substances / solutions Dispose of solutions agter one month. C3 L4 Medium Immediate Supervisor and user Notes October 2002 . Timing.