Risk Management in Materials Engineering

1. Risk Management in Materials Engineering Prof Wayne Cook Safety Officer Room 153/Bldg 19 Phone 54926 wayne.cook@eng.monash.edu.au

2. 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

3. 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

4. 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

5. 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

6. 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

7. 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

8. Manual Handling Hazards

9. 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.

11. 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

12. 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

13. Risk control worksheet

14. Risk assessment

15. Safe Work Instructions for Equipment/machinery/technique/process

16. Equipment and Processes

18. 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

19. 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

20. 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

21. Safe Work Instructions for Equipment/machinery/technique/process

22. Chemical Exposure Hazards boiling point and use temperature determines volatility

29. 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)

30. 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

31. 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

32. 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

33. INTERMISSION

34. not expired Hazardous Local contacts MSDSs e.g hexanedithiol

35. risk phrases

36. 5 - Fire Fighting MeasuresEXTINGUISHING MEDIA cleaning up

37. how to work with the material boiling point give volatility information

38. chemical interactions risk phrases

39. 12 - Ecological Information DG class - miscellaneous Packing group risk phrases

40. Hazardous Explosive, irritating Dibenzoyl peroxide - MSDS

41. Incompatibilities DG Class 5.2 - Organic peroxide

42. Bretherick - dibenzoyl peroxide

43. Shock sensitive

44. Explosion risk with accelerators

45. Hazardous Toxic, explosive Picric acid - MSDS

46. Flammable solid risk phrases

47. Picric acid - Bretherick

48. Shock sensitive, particularly with salts (etchant products)

49. Hazardous Explosive Toxic, corrosive Perchloric acid - MSDS

50. DG 5.1 Oxidizer DG subclass 8 Corrosive