Assessment Details
Campus: Clayton / Faculty: EngineeringDepartment: Engineering / Building: 37
Room No: 186
Other:
Assessment Date:17 October 2007
Area/ Task/ Process Description: Practical exercise P-50 “Surface Coatings”
Assessment Team:
Name / SignatureJulian Rosalie
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)
3. Cross reference the consequence and likelihood to determine the risk (Risk)
4. Outline the preventative/corrective action (Corrective Actions/Risk Controls)
5. Provide a realistic date by which the actions should be completed/implemented (Timing)
6. Nominate the person responsible for the follow of the actions (Responsibility)
Corrective Action Planning & Review
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 assessment is to implement effective and sustainable controls to prevent or significantly reduce the chance of injury, illness or exposure.
4 levels of controls define the hierarchy. The top two levels Elimination/ Substitution and Engineering Controls are by far the most effective in preventing or reducing risks because they rely much less on human behavior, 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.
October 2002
Metallographic preparation
Hazard No. /Description of Hazard
/ Corrective Actions/ Risk ControlsE6 / Manual handling hazard.
Polishing and grinding samples for extended periods / Take a break if polishing or grinding for long periods (greater than 0.5h).
Maintain a good posture and avoid holding samples awkwardly.
Avoid using excessive pressure when grinding.
Consequence; M4 / Likelihood; D3 / Risk; Medium (Low with control measures) / Timing;
ongoing / Responsibility; student
H1 / Body parts getting caught in the polisher or grinding machines. Abrasion of the fingers etc / Remain alert when using the machines.
Gloves may be worn if desired.
Do not use higher speeds than necessary on the variable speed machines. (This will also reduce sample heating and generally improve sample quality).
Consequence; C5 / Likelihood; L5 / Risk; Low / Timing;
ongoing / Responsibility; operator
H1 / Samples may become uncontrolled if inadequately held / Ensure adequate grip on the samples by using both hands.
Do not use higher speeds than necessary on the variable speed machines. (This will also reduce sample heating and generally improve sample quality).
Do not use excessive pressure when grinding samples.
Gloves may be worn if desired.
Safety glasses are mandatory for all users of the metallography room.
Consequence; / Likelihood; / Risk; / Timing;
ongoing / Responsibility; operator
H2 / Spill hazard. Water may splatter on to the floor if the taps are fully opened during grinding process / Water spills should be cleaned up immediately.
Make sure the taps are opened slowly and does not squirt water on to the floor.
Consequence; C4 / Likelihood; L4 / Risk; Medium / Timing;
ongoing / Responsibility; operator
C1 / Inhalation of ethanol and compressed air mixture used when cleaning samples between polishing and grinding steps.
Boiling point of ethanol is 78oC. / Fume-hood requires annual inspection.
Make sure the spray is directed away from the person and into the fume cupboard.
Fume cupboard is switched on and operating and that the sash is lowered as far as practical to ensure good vapour extraction.
Consequence; C5 / Likelihood; L5 / Risk; Low / Timing;
ongoing / Responsibility; operator
C1 / Skin coming into contact with the ethanol and compressed air mixture used when cleaning samples between polishing and grinding steps.
Boiling point of ethanol is 78oC. / Make sure the spray is directed away from the person and into the fume cupboard.
Fume cupboard is switched on and operating
Wear PPE including gloves and lab coat or long sleeved top and safety glasses.
If comes into contact with skin wash with large amounts of water, and if the irritation persists seek medical advice
Consequence; C3 / Likelihood; L5 / Risk; Low / Timing; ongoing / Responsibility; operator
C1 / Airborne droplets of ethanol entering the eyes during cleaning of samples
Boiling point of ethanol is 78oC. / Make sure the spray is directed away from the person and into the fume cupboard.
Fume cupboard is switched on and operating with the sash lowered as far as practical.
Wear safety glasses when in the metallography room.
If comes into contact with skin wash with large amounts of water and if the irritation persists seek medical advice
Consequence; C3 / Likelihood; L5 / Risk; Low / Timing; ongoing / Responsibility;
operator
C1 / Skin contact with Kerosene used as lubricant during polishing process
Risk phases associated with Kerosene (R10 R38 R65) (S2 S24 S62 S36/37 ) / Wear appropriate personal protection equipment such as lab coat or long sleeve top and gloves during the use of polishing apparatus.
If comes into contact with skin then wash affected area thoroughly with soap and water. Remove contaminated clothing and wash before reuse or discard. If symptoms develop seek medical attention.
Do not use excessive amounts of kerosene; the polishing wheel need only be damp, not dripping.
Consequence;
C3 / Likelihood;
L5 / Risk;Low / Timing; / Responsibility;
operator
H7 / Kerosene is flammable. Flash point is approximately 40oC
Risk phases associated with Kerosene (R10 R38 R65) (S2 S24 S62 S36/37 ) / Make sure the polishing wheel is lubricated with kerosene.
Do not apply excessive pressure on to the sample.
Make sure no faulty electrical cords are present that may result in sparks
Naked flames, sparks and sources of ignition should be kept away
Cover the polishing wheel when not in use to limit evaporation of kerosene.
Consequence; C4 / Likelihood; L5 / Risk; Low / Timing; ongoing / Responsibility;
operator
H4 / Electrical hazards associated with the use of 240V electrical equipment / Ensure that portable electrical equipment is tested and tagged in accordance with AS3760.
Visually inspect leads, equipment, etc, before use to detect any damage, etc, prior to using the equipment.
Consequence; / Likelihood; / Risk; / Timing; ongoing / Responsibility;
operator
H7 / Physico-chemical hazard; acidity etchants (cupric sulphate, Hydrochloric acid and ethanol)
Risk of burns to skin from hydrochloric acid and cupric sulphate during handling and use of the solution.
Solution constituents collectively provide risk phases (R34, R37, R22, R36/38) hazard group C
There have been no recorded incidents within SPME of burns due to HCl and CuSO4 / PPE to be worn Wear gloves, safety glasses, lab coat, long trousers and enclosed shoes
Decanting to be done within a fume cupboard with the sash lowered so as to protect the face.
Winchester immediately returned to storage cabinet after decanting.
Winchester to be carried either with two hands around body of the winchester or in a safety carrier.
Two people to be present – safety shower and eye wash to be available within preparation laboratory.
Consequence; C2 / Likelihood; L4 / Risk; Low / Timing;
ongoing / Responsibility;
demonstrator to monitor use of etchant.
Students to adhere to directions.
C1 / Etchant; (cupric sulphate, Hydrochloric acid and ethanol)
Inhalation of fumes from the solution during the etching process. Note: the greatest risk is during initial decanting of the solution.
Solution boiling point > 64.5°C, solution at room temperature when decanting and use.
Solution constituents collectively provide risk phases (R34, R37, R22, R36/38) hazard group C
There have been no recorded incidents within SPME of inhalation of fumes from the solution. / The solution only opened, decanted, etc, in a fume cupboard. Sash height to be lowered at least to the height indicated by black horizontal line yellow diamond. Previous fume cupboard flow test date to be within the last 12 months.
The winchester of solution is to be kept loosely sealed when outside the fume cupboard. Winchester immediately returned to storage cabinet after decanting. Winchester to be carried either with two hands around body of winchester or in a safety carrier.
Two people present at all times.
Consequence; C3 / Likelihood; L5 / Risk; Low / Timing;
ongoing / Responsibility;
Demonstrator to monitor students during use of etchant.
H7 / Pressure built ups in bottles containing solutions when stored for long periods of time / Do not tighten the lid when storing solution and use self venting lids. Do not store solution for long periods of time and dispose according to safety requirements
Consequence; C2 / Likelihood; L5 / Risk; Medium / Timing;
monthly / Responsibility;
Demonstrator
Formation of saturated solutions due to ethanol evaporation over very long periods of time
There have been no recorded incidents within SPME of formation of saturated solutions during storage / Keep the solution cool and away from heat sources and discard the solution after a month.
During use make sure that there is no crystallites formed around the mouth of the bottle. If there is crystallites present wash carefully with water.
Consequence; C2 / Likelihood; L5 / Risk; Medium / Timing; ongoing / Responsibility; operator
C1 / Skin or eye contact from the solution during the etching process. Note: the greatest risk is during initial decanting of the solution.
Solution boiling point > 64.5°C, solution at room temperature when decanting and use.
Solution constituents collectively provide risk phases (R34, R37, R22, R36/38) hazard group C
There have been no recorded incidents within SPME / The solution only opened, decanted, etc, in a fume cupboard. Sash height to be lowered at least to the height indicated by black horizontal line yellow diamond. Previous fume cupboard flow test date to be within the last 12 months.
PPE to be worn – Wear gloves, safety glasses, lab coat, long trousers and enclosed shoes
Two people to be present at all times.
Consequence; C3 / Likelihood; L5 / Risk; Low / Timing;ongoing / Responsibility; Demonstrator to monitor students,
Consequence; / Likelihood; / Risk; / Timing; / Responsibility;
Microhardness Testing
Description of Hazard
/ Corrective Actions/ Risk ControlsE2 / Sustained awkward posture while positioning sample for hardness testing / Student to take a 10 minute break per hour operating machine (i.e.50 minutes work then 10 minute break) Move and stretch
Consequence;
Minor (M4) / Likelihood;
Short periods (D4) / Risk;
Low / Timing;
Immediate / Responsibility;
Demonstrator (to inform student)
Student to undertake
H4 / Electrical hazard associate with mains voltage equipment (power supply for microhardness tester) / Ensure that electrical equipment has been tested and tagged with the previous 12 months. .
Check leads for damage or fault before operating
Consequence;
Minor (C4) / Likelihood;
Highly unlikely (L5) / Risk;
Low / Timing;
Immediate / Responsibility;
Technician to conduct periodic maintenance
Demonstrator to check
Student to check
E6 / Risk of eyestrain resulting after prolonged periods of work / Ensure lab is adequately lit while working
Student to take a 10 minute break per hour operating machine (i.e.50 minutes work then 10 minute break). Rest eyes during break
Consequence;
M4 / Likelihood;
D5 / Risk;
Low / Timing;
Immediate / Responsibility;
Student to inform demonstrator if they fell lighting is inadequate
Optical Microscopy
Description of Hazard
/ Corrective Actions/ Risk ControlsE2 / Sustained awkward posture while observing and sketching microstructures / Student to take a 10 minute break per hour operating microscope (i.e.50 minutes work then 10 minute break) Move and stretch
Consequence;
Minor (M4) / Likelihood;
Short periods (D4) / Risk;
Low / Timing;
immediate / Responsibility;
Demonstrator (to inform student)
Student to undertake
H4 / Electrical hazard associate with mains voltage equipment (microscope lights + computer mains and CCD power when using CCD-microscope) / Ensure that electrical equipment has been tested and tagged with the previous 12 months. .
Check leads for damage or fault before operating
Consequence;
Minor (C4) / Likelihood;
Highly unlikely (L5) / Risk;
Low / Timing;
Immediate / Responsibility;
Technician to conduct periodic maintenance
Demonstrator to check
Student to check
E6 / Risk of eyestrain resulting after prolonged periods of work / Ensure lab is adequately lit while working
Student to take a 10 minute break per hour operating microscope (i.e.50 minutes work then 10 minute break). Rest eyes during break.
Consequence;
M4 / Likelihood;
D5 / Risk;
Low / Timing;
Immediate / Responsibility;
Student to inform demonstrator if they fell lighting is inadequate
Notes
October 2002