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Risk Management in Materials Engineering. Prof Wayne Cook Safety Officer Room 153/Bldg 19 Phone 54926 wayne.cook@eng.monash.edu.au. Person. RISK. Hazard and risk in the lab. Risk is associated with the potential interaction between the person and the hazard,

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risk management in materials engineering
Risk Management in Materials Engineering

Prof Wayne Cook

Safety Officer

Room 153/Bldg 19

Phone 54926

wayne.cook@eng.monash.edu.au

hazard and risk in the lab

Person

RISK

Hazard and risk in the lab

Risk is associated with the potential interaction between the person and the hazard,

i.e. how likely is it that the harm will result from that hazard

Hazard:

Equipment

Procedure Chemical

hazard and risk in the lab3
Hazard, High Risk

Hazard, Low Risk

Hazard and risk in the lab
  • Hazard - potential to cause harm
  • Risk - likelihood that harm will occur and the consequence
risk assessment
Risk assessment

Risk = Consequence X Likelihood

The risk assessment must take into account:

  • each hazardous substance used
  • the information on the label and the MSDS
  • the nature of the work
  • the duration of the process
  • the consequences of an accident
dose response curve chemicals only
Dose-response curve (Chemicals only)

Range of increasing effect

with increasing dose

Increasing effect 

Maximum effect range

No effect range

Increasing dose 

Hazard = Toxicity X Exposure

risk control program
Risk control program
  • PROJECT PROCEDURES: A step by step description of the project including all of the potential hazards in the project
  • RISK ANALYSIS: Based on the Project Procedures, identify the hazards in the project and undertake risk assessment and risk control of these hazards
  • RISK ASSESSMENT: Based on Risk Analysis, complete the Risk Assessment document
  • SAFE WORKING INSTRUCTIONS: Based on Risk Analysis, complete the dot points of the SWI
  • TRAINING: The Safe Working Procedures will indicate the required training e.g. Chemical handling, Equipment and X ray
  • EMERGENCY PROCEDURES: such as chemical spills will be developed from Training and Safe Working Procedures

The Risk Control Program and Worksheets can be downloaded at the bottom of the documents page from:

http://www.adm.monash.edu.au/ohse/documents/others/risk-control-program.doc

risk control program7
Risk control program

The Risk Control Program and Worksheets can be downloaded at the bottom of the documents page from:

http://www.adm.monash.edu.au/ohse/documents/others/risk-control-program.doc

slide9

Assessment

NOTE: When determining the likelihood use, frequency and/or duration as the indicator. For duration the emphasis is on an increasing scale of static muscle load over periods of minutes to hours. For frequency the emphasis is on an increasing scale of repetitive muscle force over shorter periods, seconds to minutes.

case study compression testing with instron
Case study - compression testing with Instron
  • PROJECT PROCEDURES: A step by step description
  • attach 10,000 N load cell to main cell
  • connect electricals
  • attach compression fixture to cell
  • attach base plate to crosshead
  • set up program
  • set over-load limiter
  • set displacement limiters
  • insert specimen
  • adjust crosshead position
  • close protective shield
  • commence test
  • save data
  • process data
  • reset machine
  • clean up specimen debris
  • etc

attach compression fixture to cell

attach base plate to crosshead

process data

slide12

process datapoor posture/eye strain E2 and E3 M4 (minor injury) D4 (Short periods frequently <1hr) = medium risk  take 5 min breaks; sit in proper chair

  • attach compression fixture to cell
  • attach base plate to crosshead
  • lifting heavy load E1
  •  M3 (moderate injury)
  • D5 (Short periods
  • infrequently <1hr)
  • = medium
  •  get assistance
safe work instructions for equipment machinery technique process
Safe Work Instructions for Equipment/machinery/technique/process
case study compression testing with instron at low temperature
Case study - compression testing with Instron at low temperature
  • PROJECT PROCEDURES: A step by step description
  • collect liquid N2
  • attach 10,000 N load cell to main cell
  • connect electricals
  • attach compression fixture & base plate
  • connect liquid N2 and pump
  • set up program
  • set overload limiter
  • set displacement limiters
  • insert specimen
  • adjust crosshead position
  • commence test
  • save & process data
  • reset machine
  • clean up specimen debris
  • collect liquid N2

attach 10,000 N load cell to main cell

  • connect electricals

attach compression fixture & base plate

  • connect liquid N2 and pump

commence test

equipment and process hazards
Equipment and process hazards

H1. Machinery Hazard – entanglement, crushing

H2. Gravitational Hazard – such as slip, trip

H3. Kinetic Energy Hazard –being hit by a moving vehicle or object

H4. Electrical Hazard – such as contact with an electrical conductor

H5. Stored Energy Hazard – such as pressurised containers, vessels

H6. Noise or Vibration Hazards – such as exposure to vibration

H7. Thermal Hazards – such as hot /cold surfaces or components

H8. Hazardous Conditions- equipment in poor condition, poor training

H9. Physico-chemical Hazards – corrosive or flammable chemicals

slide20

liquid N2

  • H7. Physio-chemical hazard
  • asphyxiation
  •  C1 (major injury)  L5 (highly unlikely) = high ensure room ventilation, use O2 meter, check security of piping, ensure Dewar stability

30kg of N2 = 1000 mol

= 100022L N2 gas at STP

=22 m3 N2 gas

Room 3m 5m 5m=75m3

Dilution of O2 in air is

22/75 = 0.3

O2 drops from 21 to 14 %

(not deadly)

  • commence test
  • H3. Kinetic Energy Hazard
  •  C3 (moderate injury)  L4 (unlikely) = medium use safety shield, wear safety glasses
  • attach compression fixture & base plate
  • H1. Machinery Hazard /H2. Gravitational hazard
  •  C4 (minor injury)  L4 (Unlikely) = medium get assistance
  • collect & connect liquid N2 and pump
  • H7. Thermal Hazards
  • (H4. Electrical Hazard)
  •  C3 (moderate injury)  L4 (unlikely) = medium wear safety glasses, gloves, face visor

attach 10,000 N load cell to main cellH1. Machinery Hazard/H2. Gravitational hazard C3 (moderate injury)  L4 (Unlikely) = medium get assistance, use shield

  • connect electricals
  • H4. Electrical Hazard
  •  C2 (severe injury)  L5 (highly unlikely) = medium check electrical tagging, check electrical wires
safe work instructions for equipment machinery technique process21
Safe Work Instructions for Equipment/machinery/technique/process
chemical exposure hazards
Chemical Exposure Hazards

boiling point and use temperature determines volatility

slide29

Priority One –Elimination

Don’t use the hazardous substance. Don’t use the process.

Priority Two – Substitution/Reduction

Find a safer substance or better way to perform the process.

Priority Three – Isolation

Keep it away from you.

Priority Four - Engineering Controls

Engineer a better way.

Priority Five - Procedures and Training

Priority Six – Personal Protective Equipment (PPE)

material safety data sheet and laboratory hazard register
Material Safety Data Sheet and Laboratory Hazard Register
  • These are available (by law) with all commercially available chemicals.
  • These should be obtained from the supplier and should have Australian contact details
  • When you bring chemicals into the School, please place the MSDS in the lab folder
  • A register of all hazardous substances must be available in each laboratory
  • The register contains a copy of the (MSDS) prepared by the manufacturer or importer
  • Inform the academic in charge of the lab of the presence of new chemicals so that the Register can be updated and copied to Jim Mitchell for the updating of the Emergency Information Book for each building
slide31

Dangerous Goods and hazardous substances

Hazardous substances

Chemicals that have the potential to harm human health due to either:

  • acute toxicity or chronic adverse health effects

Dangerous Goods

Goods that have dangerous physical or chemical properties that may result in immediate damage to people or property during their storage, handling or transport.

  • Effects:fire, explosion, corrosion, poisoning
dangerous goods classes
Dangerous Goods Classes

Class 1: Explosives (Special licence required)

Class 2: Compressed/Liquefied Gases

Class 3: Flammable/Combustible Liquids

Class 4: Flammable Solids

Class 5: Oxidisers

Class 6.1: Poisons

Class 6.2: Infectious substances

Class 7: Radioactive substances

Class 8: Corrosives

Class 9: Miscellaneous

Class R: Restricted

msdss e g hexanedithiol

not expired

Hazardous

Local contacts

MSDSs e.g hexanedithiol
slide37

how to work with the material

boiling point give volatility information

slide39

12 - Ecological Information

DG class

- miscellaneous

Packing group

risk phrases

slide41

Incompatibilities

DG Class 5.2

- Organic peroxide

slide46

Flammable solid

risk phrases

perchloric acid msds

Hazardous

Explosive

Toxic, corrosive

Perchloric acid - MSDS
slide50

DG 5.1

Oxidizer

DG subclass 8

Corrosive

slide53

Explosion risk

Explosion risk for electropolishing

case study new etching solution
Case study - new etching solution

30% of 85% H3PO4/30% CH3COOH at room temp

MSDS info:

  • acetic acid - strong acid (Class: 8 corrosive)
  • Subrisk: class 3 (flammable liquid)
  • R-PHRASES: 10 35
  • Flammable. Causes severe burns.
  • S-PHRASES: 26 36/37/39 45
  • In case of contact with eyes, rinse immediately with plenty of water and seek medical advice. Wear suitable protective clothing, gloves, and eye/face protection. In case of accident or if you feel unwell, seek medical advice immediately (show the label where possible).
  • phosphoric acid - strong acid (Class: 8 corrosive)
  • R-PHRASES: 34
  • Causes burns.
  • S-PHRASES: 26 36/37/39 45
  • In case of contact with eyes, rinse immediately with plenty of water and seek medical advice. Wear suitable protective clothing, gloves, and eye/face protection. In case of accident or if you feel unwell, seek medical advice immediately (show the label where possible).
bretherick interactions

no interactions,

not oxidizing

heat generation

Bretherick - interactions
procedure for use of solution
Procedure for use of solution
  • PROJECT PROCEDURES: A step by step description
  • addition of 30 g of 85% H3PO4 to 60 g of cold water slowly
  • addition of 30 g of CH3COOH to cold solution slowly
  • transfer of solution into properly labeled bottle
  • placing of specimen into plastic or glass container (no interactions) and addition of 10 cc of solution
  • etching of metal with acetic acid/phosphoric acid solution
  • removal of specimen and rinsing under water stream
  • collection of waste acetic acid/phosphoric acid solution in labelled bottle for disposal by Chemsal
volatility in use 10cc
Volatility in use (10cc)

acetic acid

BP= 117°C at 760mm

 medium volatility

at RT, small quantity

 moderate risk

phosphoric acid

BP= N/A at 760mm

 low volatility at RT

small quantity

 low risk

inhalation potential
Inhalation potential

acetic acid

moderate risk

room ventilation  likely inhalation

fume hood  highly unlikely inhalation

phosphoric acid

low risk

room ventilation  unlikely inhalation

fume hood  highly unlikely inhalation

inhalation risk

S

Inhalation risk

acetic acid

room ventilation  likely inhalation

fume hood  highly unlikely inhalation

Hazard Group D (R26 toxic by inhalation)

 room ventilation  high risk

 fume hood  low risk

phosphoric acid

room ventilation  unlikely inhalation

fume hood  highly unlikely inhalation

Hazard Group C (R36/37/38

irritating to respiratory system)

 room ventilation or fume hood  low risk

skin absorption risk
Skin absorption risk

acetic acid

wearing gloves and safety glasses

 unlikely skin contact

Hazard Group C (R34 causes burns)

 low risk

phosphoric acid

wearing gloves and safety glasses

 unlikely skin contact

Hazard Group C (R35 causes severe burns)

 low risk

safe work instructions for equipment machinery technique process61
Safe Work Instructions for Equipment/machinery/technique/process

If a hazard has been assessed, and, after taking into account all normal methods of risk minimization, the risk is still medium or high then a Safe Work Instruction (SWI) must be prepared. All equipment must also have a SWI.

A proforma of the SWI is at: http://www.eng.monash.edu.au/mat/ohs

/safework_instructions_Sep_23.doc

All RAs and SWIs with risks which remain as medium or high must be checked and countersigned by the Safety Officer or Deputy or their delegate.

slide64

Priority One –Elimination

Don’t use the biological hazard. Don’t use the process.

Priority Two – Substitution/Reduction

Find a less hazardous organism or find a better way to perform the process.

Priority Three – Isolation

Keep it away from you.

Priority Four - Engineering Controls

Engineer a better way.

Priority Five - Procedures and Training

Priority Six – Personal Protective Equipment (PPE)

ionising radiation external exposure hazard
Ionising Radiation – External Exposure Hazard

* Equivalent dose rate is typically used for this risk assessment process.

+ Dose rates above 1500 Sv/h present an unacceptable risk regardless of the exposure time.

protocol for new equipment or transfer of equipment

Machinery or Equipment either delivered or to be modified or relocated

Machinery or Equipment either delivered or to be modified or relocated

Machinery or Equipment either delivered or to be modified or relocated

Machinery or Equipment either delivered or to be modified or relocated

Machinery or Equipment either delivered or to be modified or relocated

Machinery or Equipment either delivered or to be modified or relocated

Machinery or Equipment either delivered or to be modified or relocated

“Safety Sign Off “ Tag attached to equipment (PO)

“Safety Sign Off “ Tag attached to equipment (PO)

“Safety Sign Off “ Tag attached to equipment (PO)

“Safety Sign Off “ Tag attached to equipment (PO)

“Safety Sign Off “ Tag attached to equipment (PO)

“Safety Sign Off “ Tag attached to equipment (PO)

“Safety Sign Off “ Tag attached to equipment (PO)

Installation Approval prior to commissioning

(PO and/or SO and/or HSR and/or OHSE)

Installation Approval prior to commissioning

(PO and/or SO and/or HSR and/or OHSE)

Installation Approval prior to commissioning

(PO and/or SO and/or HSR and/or OHSE)

Installation Approval prior to commissioning

(PO and/or SO and/or HSR and/or OHSE)

Installation Approval prior to commissioning

(PO and/or SO and/or HSR and/or OHSE)

Installation Approval prior to commissioning

(PO and/or SO and/or HSR and/or OHSE)

Installation Approval prior to commissioning

(PO and/or SO and/or HSR and/or OHSE)

Installation Sign-Off

(PO and/or SO and/or HSR and/or OHSE)

Installation Sign-Off

(PO and/or SO and/or HSR and/or OHSE)

Installation Sign-Off

(PO and/or SO and/or HSR and/or OHSE)

Installation Sign-Off

(PO and/or SO and/or HSR and/or OHSE)

Installation Sign-Off

(PO and/or SO and/or HSR and/or OHSE)

Installation Sign-Off

(PO and/or SO and/or HSR and/or OHSE)

Installation Sign-Off

(PO and/or SO and/or HSR and/or OHSE)

Commissioning Approval Prior to Operation

(PO and/or SO and/or OHSE)

Commissioning Approval Prior to Operation

(PO and/or SO and/or OHSE)

Commissioning Approval Prior to Operation

(PO and/or SO and/or OHSE)

Commissioning Approval Prior to Operation

(PO and/or SO and/or OHSE)

Commissioning Approval Prior to Operation

(PO and/or SO and/or OHSE)

Commissioning Approval Prior to Operation

(PO and/or SO and/or OHSE)

Commissioning Approval Prior to Operation

(PO and/or SO and/or OHSE)

Checklist completed

(PO, SO, HSR and OHSE)

Checklist completed

(PO, SO, HSR and OHSE)

Checklist completed

(PO, SO, HSR and OHSE)

Checklist completed

(PO, SO, HSR and OHSE)

Checklist completed

(PO, SO, HSR and OHSE)

Checklist completed

(PO, SO, HSR and OHSE)

Checklist completed

(PO, SO, HSR and OHSE)

SAFETY SIGN OFF

Approval to Operate

Remove Tag

(PO, SO, HSR and OHSE)

SAFETY SIGN OFF

Approval to Operate

Remove Tag

(PO, SO, HSR and OHSE)

SAFETY SIGN OFF

Approval to Operate

Remove Tag

(PO, SO, HSR and OHSE)

SAFETY SIGN OFF

Approval to Operate

Remove Tag

(PO, SO, HSR and OHSE)

SAFETY SIGN OFF

Approval to Operate

Remove Tag

(PO, SO, HSR and OHSE)

SAFETY SIGN OFF

Approval to Operate

Remove Tag

(PO, SO, HSR and OHSE)

SAFETY SIGN OFF

Approval to Operate

Remove Tag

(PO, SO, HSR and OHSE)

Protocol for new equipment or transferof equipment
faculty of engineering project process equipment safety safety sign off procedure flowchart
Faculty of Engineering Project/Process/Equipment Safety Safety Sign-off Procedure Flowchart

(Modifications to projects / processes, etc, that introduce new/additional hazard groups or result in significant changes to risk)

safe work instructions for equipment machinery technique process73
Safe Work Instructions for Equipment/machinery/technique/process
slide74

4.Personal protective equipment to be used:

For example:

Safety glasses/goggles/face shield; protective shoes/rubber boots/waders; gloves; laboratory coat/back-opening gown; safety helmet/hair fasteners/net; ear plugs/muffs; respiratory protection.

5.The environment where the task is to be undertaken:

For example:

Fume cupboard, glove box, local exhaust ventilation, biosafety cabinet, radiation laboratory.

6.Step by step procedures for task

For example:

Project walk through - may itemise individual tasks.

7.Clean-up procedures

For example:

Swarf removal, decontamination of glassware, cleaning of benches, storage of used materials, carcass removal.

8.Waste disposal procedures

For example:

For chemical/biohazardous/radioactive waste, broken glassware, wood dust, rags.

9.Emergency procedures

For example:

For chemical spill, power outage, explosion

10.After hours access procedures

For example:

Specific requirements to perform activities after hours, eg, prohibit activity, two people in room, buddy system, etc.

11.Associated Documents

For example:

Risk assessments, MSDSs

Prepared by: ……………………………..Date: ……………………Signed:……………………..