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

 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.

Heat Treatment
Salt Baths
1Description of Hazard
Hazard Corrective Actions/ Risk Controls
No.
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. Wear heat resistant
into the salt baths and this may cause salt to gloves, face shield and safety glasses.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.
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. Visually inspect the leads, equipment
H4 etc. 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,
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. Make
slipping hazard. 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. 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. occurs. Contact doctor or poisons information
Temposal used R8/R36/R25/S46 Hazard Group C centre if swallowed. It is irritating to the eye so
wash with water and contact doctor. 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
 Salts are ignitable if stored with combustible Make sure salts are stored away from
materials or comes into contact with flammable combustible materials.
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
Oil baths
2Description of Hazard
Hazard Corrective Actions/ Risk Controls
No.
The temperature of the oil baths can be up to Wear heat resistant gloves and safety glasses
H7 200oC. 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. Wear heat resistant gloves, face
steam and by splatter molten salt over large distances. 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.
Visually inspect the leads, equipment etc. 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
slipping hazard. This is likely to occur during taking
samples out and putting into quenching water bath
H2
Consequence C2 Likelihood L5 Risk medium
Oil and water spills should be cleaned up immediately.
Make sure quenching bucket is not full so water will
not drip during movement of the bucket. Make sure
the quenching water bucket is close to the oil bath

Timing Responsibility

October 2002
Tensile Testing Hounsfield
3
Hazard 4Description of Hazard Corrective Actions/ Risk Controls
No.
H1 Crushing hand during set-up No change to existing controls.
Demonstrator to supervise set-up and sample change-over.
Machine is to be operated by SPME trained staff only.
Use caution when loading samples. Set crosshead limit
switches carefully before loading samples.
Keep other staff away from computer when loading sample
to avoid unexpected operation.
Consequence; Likelihood; Risk; Timing; Responsibility;
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. machine.
When handling load cells or heavy grips, the wearing of
steel capped safety shoes should be considered.

Consequence; Likelihood; Risk; Timing; Responsibility;

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, or wear safety
compression tests or broken parts may fly out glasses.
unexpectedly, especially when removing strained but
intact samples. Ensure that there is no tension in the test piece before
removing. Safety glasses to be worn.

Consequence; Likelihood; Risk; Timing; Responsibility;

C3 L4 Medium Immediate Demonstrator (to supervise)
Student (to use PPE)

Consequence; Likelihood; Risk; Timing; Responsibility;

Consequence; Likelihood; Risk; Timing; Responsibility;

Consequence; Likelihood; Risk; Timing; Responsibility;

Consequence; Likelihood; Risk; Timing; Responsibility;

October 2002
 Hardness testing
5
Hazard 6Description of Hazard Corrective Actions/ Risk Controls
No.
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.e.50 minutes work then 10 minute break). Rest
eyes during break
Consequence; Likelihood; Risk; Timing; Responsibility;
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. Use
portable devices if fixed ones are not installed.

Check leads for damage or fault before operating

Consequence; Likelihood; Risk; Timing; Responsibility;
C4 L5 Low Immediate Student
E2 Sustained awkward posture Operator to take a 10 minute break per hour operating
machine (i.e.50 minutes work then 10 minute break) Move
and stretch

Consequence; Likelihood; Risk; Timing; Responsibility;

M4 D4 Low Immediate Student

October 2002
7Electropolishing
8Preparation
9Description of
Hazard No. 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.
perchloric/methanol solutions.
Perchloric acid only to be opened, decanted etc. in a fume
B.P. of perchloric acid = 198 C. Acid cupboard. Sash height to be lowered to at least the height indicated
o
at room temperature when decanting by horizontal line. Previous flow tst to be within the last 12 months
and at -25(+/- 5)oC when mixing Winchester of acid is to be kept sealed when outside the fume
(Low volatility); Up to 0.5L cupboard. Winchester immediately returned to storage cabinet after
Winchester of acid (Lowv olatility decanting. Winchester to be carried either with two hands around
when in use); decant and mix in fume body of vessel or in a safety container.
cupboard. (Inhalation potential
unlikely); Hazard Group E R45 (Low
risk of inhalation)

Consequence; Likelihoo Risk; Timing; Immediate Responsibility;

C3 d; 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.
methanol solution.
PPE to be worn long high grade PVC gloves, face shield, plastic
Hazard group E R45. apron, long sleeves and long trousers, enclosed shoes.
Decanting to be performed within a fume cupboard with sash
lowered so as to protect the face.

Winchester immediately returned to the storage cabinet after

decanting. Winchester to be carried either with two hands around
body of vessel or in a safety container.

Safety shower and eye wash available within lab

Consequence; Likelihoo Risk; Timing; Responsibility;

C2 d; 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.
solution.
Decanting to be performed within a fume cupboard with sash
Hazard group C R11, R23/25 (Low lowered
Risk of inhalation)
Winchester immediately returned to the storage cabinet after
o
Methanol boiling point =64.5 C. decanting. Winchester to be carried either with two hands around
Methanol at room temperature when body of vessel or in a safety container.
decanting and at -25(+/-5)oC when
mixing. (Medium volatility);upto 2.5L
Winchester of Methanol (High
volatility during use); decant and mix
in fume cupboard (Inhalation potential
highly unlikely)

October 2002
 Consequence; Likelihoo Risk; Timing; Responsibility;
C2 d; 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.
has the potential to boil solution with
attendant risk of fire. Minimise possible contamination of the soltution by triple washing
Winchesters and equipment with clean fresh water before use.
Substitute methanol for ethanol in cooling and rinsing operations.

Ensure that there are no sources of ignition, heat, spartks or flame

in or in the vicinity of the fume cupboard during mixing.

Methanol to be cooled to -25(+/-5)oC by immersing beaker in

methanol cooled with liquid nitrogen before addition of acid.
perchloric acid to be added slowly to methanol (never vice versa)
while monitoring the temperature of the methanol.
Maintain the temperature of the methanol at -25(+/-5)oC during
mixing. Tae particular care to ensure the solution temperature does
not rise above the flashpoint for methanol (11oC) during mixing.

PPE to be worn long high grade PVC gloves, face shield, plastic
apron, long sleeves and long trousers, enclosed shoes.
Decanting to be performed within a fume cupboard with sash
lowered so as to protect the face.

Consequence;C Likelihoo Risk; Timing; Responsibility;

4 d; Low
L5
H7 Possible explosion of Winchester
following decanting of the solution
due to evolution of gas from solution.
One incident recorded in Sep 2000 in
which procedures were not followed.
A solution was left tightly capped in
direct sunlight and not collected and
appropriately stored.
Immediate Technician
Winchesters containing perchloric/methanol mixtures are to be
loosely capped and not tightly sealed.
Minimise possible contamination of the soltution by triple washing
Winchesters and equipment with clean fresh water before use.
Substitute methanol for ethanol in cooling and rinsing operations.
Store prepared solution in a glass Winchester in a ventilated
cabinet away from incompatible substances and light.

Ensure that there are no sources of ignition, heat, sparks or flame

in the close to the storage area.

Ensure that the solution temperature does not rise above 35oC
during storage

Consequence; Likelihoo Risk; Timing; Responsibility;

C4 d; Low
C5

October 2002
Handling and use
Hazard 10Description of Hazard
No. Corrective Actions/ Risk Controls

C1 Inhalation of perchloric acid fume during Solution to be handled by researcher inhalation risk to
electropolishing. students during set-up thus minimized.

Hazard Group E R23,R26, R36, R45 (Low risk of Winchester of acid is to be kept sealed when outside the
inhalation) storage cabinet. Winchester immediately returned to storage
cabinet after decanting. Winchester to be carried either with
o
B.P. of perchloric acid = 198 C. Acid at room two hands around body of vessel or in a safety container.

temperature when decanting and at -25(+/- 5)oC

when mixing (Low volatility); Up to 2.5L
Winchester of acid (Lowvolatility when in use);
decant and mix in fume cupboard. (Inhalation
potential unlikely);

Consequence; Likelihood; L5 Risk; Medium Timing; Immediate Responsibility;

C3 Technician

C1 Risk of burns to skin from perchloric acid during PPE to be worn safety glasses, lab coat, long sleeves and
handling and use of perchloric / methanol solution. long trousers, enclosed shoes.

Hazard group E 23,25,36,45 Winchester immediately returned to the storage cabinet after
pouring. Winchester to be carried either with two hands
around body of vessel or in a safety container.

Safety shower and eye wash available within lab

Consequence; Likelihood; Risk; Timing; Responsibility;
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. be loosely capped and not tightly sealed.

Minimise possible contamination of the soltution by triple

washing Winchesters and equipment with clean fresh water
before use. Substitute methanol for ethanol in cooling and
rinsing operations.

Store prepared solution in a glass Winchester in a ventilated

cabinet away from incompatible substances and light.

Ensure that there are no sources of ignition, heat, sparks or

flame in the close to the storage area.

Ensure that the solution temperature does not rise above

35oC during storage

Consequence; Likelihood; Risk; Timing; Responsibility;

C4 C5 Low Immediate Demonstrator

October 2002
H7 Possible explosion or fire resulting from the use of Minimise quantities of electropolishing solution (1.5L max)
perchloric acid / methanol solutions or methanol during and methanol (3L max) within the fume cupboard at a ll
the polishing process, due to evolution of gases and / or times. Only one type of electropolishing solution within the
esters from the solution. fume cupboard at any one time.

No reported incidences of fire or explosion during Do not seal Winchester lids leave loosely capped to allow
electropolishing operations. for the evolution of gases and buildup of pressure.

Visually inspect solution for discolouration, evolution of gase,

etc. on a weekly basis and before and during decanting of
solution. Immediately dispose of solutions that are
discoloured, evolving gases, etc.

Immediately return Winchesters of solution and methanol to

their respective storage cabinets following decanting.

Ensure that there are no sources of ignition, heat, sparks or

flame in or around the storage cupboard and working area.

Minimise possible contamination of solution by triple

washing equipment with clean fresh water followed by single
washing with rinsing methanol prior to use. Substitute
methanol for ethanol previously used in cooling and rinsing
operation; each user to use only their own electrolpolishing
solution; each electrolpolishing solution to be used with one
type of alloy only.

Dispose of solutions agter one month, after prac cycle is

complete or immediately upon discolouration, etc.

Consequence; Likelihood; Risk; Timing; 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. Use
portable devices if fixed ones are not installed.

Check leads for damage or fault before operating

Consequence; Likelihood; Risk; Timing; Responsibility;

Minor (C4) Highly unlikely Low Immediate Operator, supervisor, technician
(L5)
E2 Manual handling hazard associated with removing ad Care with transport.
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.

NO reported instances of such manual handling injuries

within SPME
Consequence; Likelihood; Risk; Timing; Responsibility;
M4 D5 Low Immediate Technician
11

October 2002
Storage
12Description of Hazard
Hazar Corrective Actions/ Risk Controls
d No.
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. sealed.

Solution boiling point > 64.5oC, solution at room
temperature (Medium volatility), up to 25L of solutions
in cupboard but with caps on loosely (assume medium
volatility during use);room ventilation (inhalation
potential Likely)
Visually inspect solution for discolouration, evolution of
gase, etc. on a weekly basis and before and during decanting
of solution. Immediately dispose of solutions that are
discoloured, evolving gases, etc.

Hazard Group E R23,26,36,45 Dispose of solutions after one month, after prac cycle is
complete or immediately upon discolouration, etc.

All spills to be dealt with immediately.

Consequence; Likelihood; Risk; Timing; Responsibility;

C3 L2 Medium

October 2002
H7 Possible expolosion or fire during the storage of Minimise quantity of electropolishing solutions in cupboard
perchloric acid / methanol solutions, due to evolution of max 25L.
gas and / or esters from the solution.
Winchesters to be kept loosely capped rather than tightly
sealed.

Visually inspect solution for discolouration, evolution of

gase, etc. on a weekly basis and before and during decanting
of solution. Immediately dispose of solutions that are
discoloured, evolving gases, etc.

Ensure that there are no sources of ignition, heat, sparks or

flame in or around the storage cupboard and working area.

Minimise possible contamination of solution during

preparation by triple washing equipment with clean fresh
water prior to use. Substitute methanol for ethanol previously
used in cooling and rinsing operation;

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. Substitute
methanol for ethanol previously used in cooling and rinsing
operation; each user to use only their own electrolpolishing
solution; each electrolpolishing solution to be used with one
type of alloy only.

Store solutions in glass Winchesters away from incompatible

substances / solutions

Dispose of solutions agter one month, after prac cycle is

complete or immediately upon discolouration, etc.

Maintain the temperature of solutions below 35oC at all

times not that toom 186 has 24 hour air conditioning.
Provide supervisors and users with documented safe work
procedures; provide adequate supervision to users. Users are
not to be licensed to use electropolishing solutions until they
have completed safety induction.

Consequence; Likelihood; Risk; Timing; Responsibility;

C3 L4 Medium Immediate Supervisor and user

Notes

October 2002