Occupational Health, Safety & Environment
Risk Control Worksheets
ASSESSMENT DETAILS
Campus:
Clayton
Faculty:
Engineering
Department:
Materials Engineering
Building:
37
Room No:
G186
Other:
Assessment Date:
Area/ Task/ Process Description:
Electrolytic polishing of steels and its alloys by the 5% of Perchloric Acid and 95% of Methanol, at –25±5oC in fume
cupboard. To be stored in a vented, corrosive proof cabinet.
Assessment Team:
Investigator
Name of Researcher
Name of Project Supervisor
Name of Academic in charge
Phone #
55348
59294
59605
Signature
HOW TO USE THIS WORKSHEET
1.
2.
3.
4.
5.
Review the identification section of each of 5 major hazard categories on the Risk Assessment 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)
Use the appropriate matrix to assess
 The possible outcome presented by each hazard (Consequence)
 The possibility of that outcome occurring (Likelihood)
 The potential level of injury or illness from the outcome (Risk)
Outline the preventative/corrective action (Corrective Actions/Risk Controls)
Provide a realistic date by which the actions should be completed/ implemented (Outlook)
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
HEIRARCHY 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.
HIERARCHY OF CONTROLS
Most
Effective
Least
Effective
1
Elimination /
Substitution
2.
Engineering
Controls
3.
Training and
procedures
4.
Personal
Protective
Equipment
Hazard
No.
C1
Description of Hazard
Corrective Actions/ Risk Controls
Inhalation of fumes from the solution during the electropolishing
process. Note: the greatest risk is during initial decanting of the
solution when it is at room temperature. The risk will be significantly
reduced when the solution is cooled.
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.
Solution boiling point > 64.5°C, solution at room temperature when
decanting and at –45°C±5°C when electropolishing and decanting
following electropolishing (Medium volatility); Up to 1.5l
winchester of solution (High volatility during use); decant, etc, in
fume cupboard (Inhalation potential Highly unlikely);
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.
Hazard Group C – R20/21/22-37, R8-36/37/38, R11, R23/25 ,
R22/36. (Low Risk of inhalation).
Provide appropriate training and supervision to users. Refer to attached
Safe Work Procedure.
There have been no recorded incidents within SPME of inhalation of
fumes from the solution during the electropolishing process.
Consequence
C3
Likelihood L5
Risk Low
Timing Immediate
Risk of burns to skin from perchloric acid during handling and use of
the solution.
Hazard Group C – R20/21/22-37, R8-36/37/38, R11, R23/25 ,
R22/36.
Bretherick’s: “Handbook of reactive Chemical Hazards”, 6th edition,
pp. 1352-1364.
C1
There have been no recorded incidents within SPME of nitric acid
burns during handling and use of solutions.
Responsibility Supervisor and user
PPE to be worn – Long high grade PVC gloves, face shield, lab coat,
long sleeves and long trousers, enclosed shoes. Wear plastic apron
when moving solution to and from the dedicated storage cabinet.
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.
Provide appropriate training and supervision to users. Refer to attached
Safe Work Procedure.
Consequence
C2
Likelihood
L4
Risk Low
Timing Immediate
Responsibility Supervisor and user
C1
Inhalation of methanol fumes from both the washing methanol and
cooling methanol during the electropolishing process, or for a spill
within the fume cupboard.
PPE to be worn – Long high grade PVC gloves, face shield, lab coat,
long sleeves and long trousers, enclosed shoes. Wear a plastic apron for
spill cleanup.
Methanol boiling point = 64.5°C, methanol at room temperature
when decanting and washing, cooling methanol at –25°C±5°C during
electropolishing (Medium volatility); Up to 2.5l winchester of
methanol (High volatility during use); decant and use in fume
cupboard (Inhalation potential Highly unlikely);
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
winchester or in a safety carrier.
Hazard Group C – R11, R23/25 (Low Risk of inhalation).
Two people to be present at all times.
There have been no recorded incidents within SPME of inhalation of
methanol fumes during the electropolishing process.
Consequence C2
Likelihood L5
Risk Low
Inhalation of fumes from the the solution or washing methanol or
cooling methanol following a spill outside the fume cupboard. Note:
the greatest risk is when the solution is at room temperature. The risk
will be significantly reduced when the solution is cooled following
the electropolishing process.
Solution boiling point >= 64.5°C, solution at room temperature
(Medium volatility); Up to 1.5l winchester of solution (High
volatility during use); Room ventilation (Inhalation potential Highly
likely);
C1
Hazard Group C – R20/21/22-37, R8-36/37/38, R11, R23/25 ,
R22/36.
For spill cleanup (>=1.5l) without appropriate organic vapour
respirator:
Consequence
C3
Likelihood L1
Provide appropriate training and supervision to users. Refer to attached
Safe Work Procedure.
Timing Immediate
Responsibility Supervisor and user
Immediately evacuate the area in the event of a spill and don an
appropriate organic vapour respirator before re-entering. Warn others to
evacuate the area, not to enter, etc. Isolate the spill from a safe distance.
Put warning signs, barriers, etc, in place.
Do not enter a laboratory where visible fumes are present, for a
spill in excess of 1.5l of solution, or following an explosion of an
electropolishing solution – full breathing apparatus will be
required in these cases.
PPE for spill cleanup – Organic vapour mask, long high grade PVC
gloves, face shield, plastic apron, long sleeves and long trousers,
enclosed shoes. Wear a plastic apron for spill cleanup.
Ensure fume cupboard is running to assist with dilution of fumes –
ensure that fume cupboard fan motor is intrinsically safe. Switch off all
electrical equipment, etc.
Risk High
Minimum of two people present at all times.
For spill cleanup (<=1.5l) with appropriate organic vapour respirator:
Consequence
C3
Likelihood L3
Risk low
Provide supervisors and users training in emergency procedures;
selection, maintenance, use, fit testing, etc, of PPE; spill cleanup
procedures; disposal of spill materials; provide documented safe work
procedures to supervisors and users; provide appropriate supervision to
users.
Timing Before using solutions
Responsibility Supervisor and user
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
Timing
H7
C1
C2
Likelihood
L5
Risk medium
weekly
Responsibility
User
Inhalation of methanol fumes during preparation of perchloric acid
solution.
PPE to be worn – Long high grade PVC gloves, face shield, plastic
apron, long sleeves and long trousers, enclosed shoes.
Methanol boiling point = 64.5°C, methanol at room temperature
when decanting and mixing (Medium volatility); Up to 2.5l
winchester of methanol (High volatility during use); decant and mix
in fume cupboard (Inhalation potential Highly unlikely);
Decanting to be done within a fume cupboard with the sash lowered so
as to protect the face.
Hazard Group C – R11, R23/25 (Low Risk of inhalation).
There have been no recorded incidents within SPME of inhalation of
methanol fumes during preparation of solutions.
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 to be present at all times.
Provide appropriate training and supervision to users. Refer to attached
Safe Work Procedure.
Consequence C2
Likelihood L5
Risk Low
Skin and eye contact with perchloric acid during measuring out and
adding perchloric acid to the alcohol mixture. Also can be a
respiratory system irritant
Hazard group C R 8-37/37/38
C1
There have been no recorded incidents within SPME of skin and eye
contact with perchloric.
Timing I
Responsibility Supervisor & technician
PPE to be worn – Long high grade PVC gloves, face shield, plastic
apron, long sleeves and long trousers, enclosed shoes.
Wear a face shield when adding to the alcohol mixture. The perchloric
acid is kept in the fume-cupboard. Perchloric acid is carefully added to
methanol in an efficient fume cupboard.
Timing I
Consequence C2
Likelihood L5
Risk Low
Inhalation of perchloric acid fumes during preparation
Hazard group C R 8-37/37/38
C!
There have been no recorded incidents within SPME of inhalation of
methanol fumes during preparation of solutions.
Responsibility Supervisor & technician
PPE to be worn – Long high grade PVC gloves, face shield, plastic
apron, long sleeves and long trousers, enclosed shoes.
Timing I
Responsibility Supervisor & technician
Vapour of perchloric acid may cause eye irritation and possible burns
Decanting of the perchloric acid to be done within a fume cupboard
with the sash lowered so as to protect the face.
Consequence C2
Likelihood L5
Risk Low
Bretherick’s: “Handbook of Reactive Chemical Hazards” 6th Edition,
pp. 1352-1364.
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.
C1
Two people to be present at all times.
Provide appropriate training and supervision to users. Refer to attached
Safe Work Procedure.
Formation of saturated solutions due to methanol evaporation over
very long periods of time
Timing Immediate
Responsibility Supervisor & technician
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 due to the evaporation of solution. If there is
crystallites present wash carefully with water.
H7
Consequence
C2
Likelihood
L5
Risk medium
Timing
Electrical hazards associated with the use of 240V electrical
equipment.
Consequence C4
Likelihood
L5
Immediate
Responsibility
User
Ensure that Earth Leakage Protection or Residual Current Devices
(RCD) are fitted to all general power circuits used. Use portable
devices if fixed devices are not installed.
Risk Low
Ensure that portable electrical equipment is tested and tagged in
accordance with AS3760.
H4
Visually inspect leads, equipment, etc, before use to detect any damage,
etc, prior to using the equipment..
Timing Immediate
Possible burns due to splashing of liquid nitrogen used for cooling.
H7
There have been no recorded incidents of burns resulting from liquid
nitrogen within SPME during mixing of acid / alcohol solutions.
Consequence C4
Likelihood
L5
Risk Low
Responsibility Supervisor & technician
Transport and store the liquid nitrogen in a suitable dewar. Minimise
the quantity used (1.5l). Ensure that the cylinder is maintained in an
upright position and cannot be physically damaged, knocked over, etc.
Place the dewar of liquid nitrogen inside the fume cupboard. Allow any
excess liquid nitrogen to vaporise within the fume cupboard following
the completion of mixing of the solution.
Slowly add the liquid nitrogen to the cooling methanol whilst
constantly stirring.
PPE to be worn – Long high grade PVC gloves, face shield, plastic
apron, long sleeves and long trousers, enclosed shoes.
Mixing to be done within a fume cupboard with the sash lowered so as
to protect the face.
The decanting of liquid nitrogen involves a risk of liquid oxygen
condensation and possible explosion. The risk is minimised by ensuring
dewar is dry before filling and dewar lid is never fixed but can blowoff.
Two people to be present at all times.
Provide appropriate training and supervision to users. Refer to attached
Safe Work Procedure.
Timing Immediate
Possible explosion or fire resulting from the use of perchloric acid/
methanol solutions or methanol during the electropolishing process,
due to evolution of gas and / or esters from the solution.
Responsibility Supervisor & technician
Minimise quantities of electropolishing solution (1.5l max) and
methanol (3l max) within the fume cupboard at all times. Only have
one type of electropolishing solution within the fume cupboard at any
one time.
Refer to Safe Work Procedure.
There have been no recorded incidents of fire or explosion during the
electropolishing process.
H7
Consequence C2
Likelihood
L5
Risk Medium
Loosely place cap on winchester of solution at all times to prevent the
buildup of pressure – do not seal tightly.
Visually inspect the solution for discoloration, evolution of gas, etc, on
a weekly basis and before and during decanting of solution.
Immediately dispose of solutions that are discolored, evolving gases,
etc. Refer to attached Safe Work Procedure.
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 flames in or
adjacent to the fume cupboard or dedicated storage cabinet.
Minimise possible contamination of the solution by: triple washing
equipment with clean fresh water and single washing with rinsing
methanol (first washing methanol, max 5 rinses) after use; single
washing of equipment with clean fresh water followed by a single
washing with rinsing methanol (second washing methanol, max 5
rinses) prior to use; substitute methanol for ethanol previously used in
cooling and rinsing operations; each user to only use their own
electropolishing solution; each electropolishing solution to be used with
one type of alloy only; each user to use their own rinsing methanol.
Dispose of solutions after 1 month or immediately upon discoloration,
etc.
Reduce the temperature of the solution to–25°C±5°C prior to the
starting the electropolishing with methanol cooled with liquid nitrogen.
Maintain the temperature of the solution at –25°C±5°C during mixing.
The evolution of gas and / or esters is inhibited at these temperatures.
Provide supervisors and users documented Safe Work Procedures;
provide appropriate supervision to users. Users are not to be licensed to
use the electropolishing solutions or equipment until they have
completed a general OHS Induction, training in: general laboratory and
chemical safety; emergency procedures; spill cleanup; Safe Work
Procedures.
Timing Immediate
Responsibility Supervisor and user
Possible asphyxiation due to a spill, outside the fume cupboard, of
liquid nitrogen used for cooling.
Room Dimensions: 7m x 2.5m x 2.7m H with a 1.2m x 0.72m cutout
Room Volume: 44.9m3
Volume of liquid nitrogen to reduce oxygen level to 19.5%: 1.0l
H9
Transport and store the liquid nitrogen in a suitable dewar. Minimise
the quantity used (1.5l). Ensure that the cylinder is maintained in an
upright position and cannot be physically damaged, knocked over, etc.
Place the dewar of liquid nitrogen inside the fume cupboard. Allow any
excess liquid nitrogen to vaporise within the fume cupboard following
the completion of mixing of the solution.
Slowly add the liquid nitrogen to the cooling methanol whilst
There have been no recorded incidents of liquid nitrogen spills within constantly stirring.
SPME during mixing and using of acid / alcohol solutions.
Immediately evacuate the room in the event of a liquid nitrogen spill in
of 1.0l or greater. Do not enter a laboratory following a spill in
Consequence C4
Likelihood L5
Risk Low
excess of 1.0l – full breathing apparatus will be required.
Two people to be present at all times.
Train users in the hazards, risks, safe handling procedures, appropriate
PPE, emergency procedures, etc.
Timing Immediate
E2
Manual handling hazard associated with removing and replacing the
winchesters of electropolishing solutions in the dedicated storage
cabinet. The 2.5l winchesters are predominantly located at floor
level. The storage cabinet door is self closing – required effort may
be increased due to being in an awkward position whilst holding the
door open and simultaneously using two hands to lift out the
winchester of solution.
There have been no recorded manual handling injuries associated
with this operation in SPME.
Consequence
M4
Likelihood
D5
Responsibility Supervisor & technician
Two people to be present at all times – second person may assist by
holding the cabinet door open for removing and replacing winchesters
of electropolishing solution.
No further measures necessary.
Timing
Risk Low
Prepared by: … ………..Date: ……………………Signed:……………………..
Immediate
Responsibility Supervisor and Users