Risk Management in Materials Engineering

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Risk Management in Materials Engineering
Prof Wayne Cook Safety Officer Room 153/Bldg
19 Phone 54926 wayne.cook_at_eng.monash.edu.au
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Hazard and risk in the lab
Hazard Equipment Procedure Chemical

• 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

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Hazard and risk in the lab

• Hazard, Low Risk

• Hazard, High Risk

• Hazard - potential to cause harm
• Risk - likelihood that harm will occur and the
  consequence

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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

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Dose-response curve (Chemicals only)
Range of increasing effect with increasing dose
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Increasing effect ?
Maximum effect range
No effect range
Increasing dose ?
Hazard Toxicity X Exposure
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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
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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
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Manual Handling Hazards
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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.
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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
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process data poor posture/eye strain E2 and
E3 ? M4 (minor injury) ? D4
(Short periods frequently lt1hr) 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 lt1hr)
• medium
• ? get assistance

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Risk control worksheet
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Risk assessment
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Safe Work Instructions for Equipment/machinery/te
chnique/process
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Equipment and Processes
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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
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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
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attach 10,000 N load cell to main cellH1.
Machinery Hazard/H2. Gravitational hazard ? C3
(moderate injury) ? L4 (Unlikely)
medium? get assistance, use shield

• 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

• connect electricals
• H4. Electrical Hazard
• ? C2 (severe injury) ? L5 (highly unlikely)
  medium? check electrical tagging, check
  electrical wires

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Safe Work Instructions for Equipment/machinery/te
chnique/process
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Chemical Exposure Hazards
boiling point and use temperature determines
volatility
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Priority One Elimination Dont use the hazardous
substance. Dont 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)
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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

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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

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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

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INTERMISSION
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MSDSs e.g hexanedithiol
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Dibenzoyl peroxide - MSDS
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Bretherick - dibenzoyl peroxide
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Shock sensitive
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Explosion risk with accelerators
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Picric acid - MSDS
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Picric acid - Bretherick
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Perchloric acid - MSDS
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Explosion risk with reductants including alcohols
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Perchloric acid - Bretherick
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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).

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Bretherick - interactions
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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

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Volatility in use (10cc)
acetic acid BP 117C 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
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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
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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
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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
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Safe Work Instructions for Equipment/machinery/te
chnique/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.mona
sh.edu.au/mat/ohs /safework_instructions_Sep_23.do
c 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.
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Biological Hazards
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Priority One Elimination Dont use the
biological hazard. Dont 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)
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Ionising Radiation Contamination Hazard
(internal)
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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.
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Attachment to radiation reference sheet
Calculating Dose Rate
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Protocol for new equipment or transferof
equipment
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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)
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Project/ Process/ Equipment Safety Sign-off
Form
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Project/ Process/ Equipment Safety Sign-off
Checklist
 
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Safe Work Instructions for Equipment/machinery/te
chnique/process

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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..
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RA salt bath heat treatment of Al alloys
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SWI salt bath heat treatment of Al alloys
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RA metallographic prep of Al alloys
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SWI metallographic prep of Al alloys
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