School of Design Faculty of Performance, Visual Arts and Communications Risk Assessment for: Roaches Pyrotec dyeing machines Assessment No: 002 PROCESS / ACTIVITY LOCATION ASSESSED BY DATE(S) Small scale dyeing of fabric samples MMF 2-09 Les Johnson 11/05/2007 WHO CAN OPERATE THE EQUIPMENT, AFTER TRAINING STAFF, POSTGRADUATES OR UNDERGRADUATES? TRAINING CAN ONLY BE GIVEN BY. FOR HIGH RISK OR LIMITED USE ITEMS LIST THE NAMED OPERATORS. Staff and postgraduates Les Johnson, Dr R. S. Blackburn and authorised postgraduates. LIKELIHOOD HAZARD(S) GROUPS OF HAZARD OF RISK ACTION PEOPLE AT POTENTIAL OCCURRENCE RANKING CONTROL MEASURES RISK (1,2 or 3) (1, 2, or 3) BY 1 Is machine performing according to specifications necessary for overall safety? All lab users 1 1 Low 2 Mixing of dye tubes between machines. All lab users 1 1 Low All 3 pyrotec machines are serviced and calibrate yearly. This is necessary because the dye tubes are pressure vessels the control side must be working correctly and not over heat. Calibration stickers on the machines date next service. Signs warning not to do this on machine. Hazard Potential (3 is High, 2 is Medium, 1 is Low) Likelihood of Occurrence (3 is High, 2 is Medium, 1 is Low) 3 = Loss of life/ Permanent disability/ Major injury; 3 = High - once or several times per day/ or per activity Extensive loss of plant; Prohibition Notice/ Prosecution. 2 = Medium - once or several times per month/ or per activity 2 = Serious Injury or illness/ Temporary disability; 1 = Low - once or few times per year / or over lifetime of project Some damage to plant, equipment; Improvement Notice 1 = Minor/ non-disabling injury or illness; Risk Ranking = Hazard Potential x Likelihood of Occurrence Minor disruption to plant, equipment 1 and 2 = LOW Risk 3 and 4 = MEDIUM Risk 6 and 9 = HIGH Risk Hierarchy of Risk Control Measures considered for HIGH / MEDIUM Risk? YES Are the control measures adequate for OUT OF HOURS WORKING? NO Technician Signed: Title: Date: Academic Supervisor Signed: Title: Date: Safety Supervisor Signed: Title: Mr Les Johnson Date: 11/05/2007
HAZARD(S) GROUPS OF PEOPLE AT RISK HAZARD POTENTIAL (1,2 or 3) LIKELIHOOD OF OCCURRENCE (1, 2, or 3) RISK RANKING CONTROL MEASURES ACTION BY 3 Thermocouple damage? Operators 2 1 Low Warning during induction about damaging them any damaged to be reported to 4 Pressure leak from dye tube. Operators 2 2 Medium Tubes must be visually inspected before use. All tube under go a yearly pressure inspection by universities insurers. 5 Pressure leak from dye tube seals. Operators 2 2 Medium Seals must be inspected before use, any damaged seals to be disposed of. 6 Temperature burns from dye tubes Operators 1 2 Low Wear protective heat resistant gloves. 7 Steam burns from dye tubes when opening. Operators 2 2 Medium Always wear protective gloves when opening the tubes. Warning sign cool down tubes before opening them. 8 Machine performance compromised when tubes On induction warn about uneven Operators 1 1 Low loaded unevenly. loading. 9 Hot surface temperature burns All lab users 1 2 Low Caution hot surface signs fixed on to machine. 10 No safe working instructions All lab users 1 1 Low Now written and available Warn during induction instruct that the Burns form Infra-red heater inside machine after 11 Operators 1 1 Low machine be allowed to cool down use. before opening the cover. 12 Sample preparation use of scissors Operators 1 2 Low Required Signatures on Front Sheet Warn users of dangers involved using scissors to prevent cuts.
Standard Operating Procedure, School of Design 002 Equipment: Pyrotec dyeing machines Supplier: Roaches International Ltd Location: 2-09 MMF Named operators: Dr Richard Blackburn, Les Johnson, postgraduate students. Operating manuals available from: Les Johnson Intended activity Piece dyeing of fabric samples Health and Safety: Please see Risk Assessment, RA 002 pyrotec COSHH Assessment must be carried out on all materials used with this equipment. PPE required Wear laboratory coat, safety glasses and disposable gloves. Tie long hair back and avoid wearing loose sleeves or jewellery. Operation: 1. Ensure cold water supply is connected to the machine as shown in the picture. 2. Turn on the Pyrotec 2000 using the switch on the right side of the machine. 3. The display screen on the front of the machine should light up. Touch the screen to continue. 4. Touch Profile Editor, this will reveal the last profile used. From here a new profile can be created, an existing profile may be loaded, or an existing profile modified.
The figures in green are the rate of temperature increase. The figures in yellow are the target temperature. The figures in red are the dwell times at the set temperature. The column in pink is for the setting of alarms and warning messages. Along the top of the display are (from left to right) rotation speed (rpm), clockwise rotation time (minutes) and anti-clockwise rotation time (minutes). The profile shown is set for a rotation speed of 10 rpm, rotating alternately 5 minutes clockwise, then 5 minutes anti-clockwise. The temperature will increase to 40 C at a rate of 5 C/min. The temperature will increase to 98 C at a rate of 2.5 C/min and then stay at 98 C for 45 minutes. The temperature will then decrease to 80 C at a rate of 1.5 C/min and then stay at 80 C for 15 minutes. Any additional steps can been seen by using the scroll buttons on the left of the display.
5. TO CREATE A NEW PROFILE a.touch a setting to select it, it should now be highlighted. Type in a new setting using the number keys in the lower part of the display and press the Enter key to accept. b. Continue until all the settings are changed satisfactorily. Once a setting is highlighted the status bar displays information about the selected item. Be sure to check there are no unwanted stages still set from the previous profile by scrolling up beyond stage 03 using the scroll buttons on the left side of the display. It is advisable to set the profile to cool at the maximum rate (7 C/min) to a safe working temperature at the end of the profile to reduce the risk of scalding or burning when removing the dyeings. c.touch Edit Profile Name to create a new name for the new profile. d. Type in a new name for the profile using the letter and number keys and touch Enter to accept. Then touch the green Esc button at the top left corner of the display to return to the previous screen. e.touch the picture of a floppy disc to save the new profile. Select a slot in which to save the new profile. Use the arrow buttons to view higher or lower slots. When the desired slot is highlighted touch the Enter key to save the new profile. If there is an existing profile in the slot it will be overwritten. Touch the green Esc button at the top left corner of the display to return to the previous screen. 6. TO OPEN AN EXISTING PROFILE a.touch the picture of a folder to open an existing profile.
b. Select a profile to load. Use the arrow buttons to view higher or lower slots. When the desired profile is highlighted touch the Enter key to load the new profile. At ant point touching the green Esc button at the top left corner of the display will return the display to the previous screen. 7. TO EDIT AN EXISTING PROFILE a.to edit an existing profile firstly open the profile using the procedures outlined in point 6. b. The profile may then be modified using the procedures outlined in point 5. The modified profile can be saved in the original version s slot without need for a name change if desired. The previous version will be overwritten. 8. In order to run a profile the profile must be loaded. With the correct profile displayed on screen, touch the Load Profile button. 9. Select the bath (compartment) to run the profile. Both baths may be selected if the profile is to be run in both. The selected baths should be highlighted in green. Touch the Enter button to confirm the selection. 10. Touch the green Esc button to return to the main Edit Profile screen.
11. Touch the green Esc button to return to the main menu screen. 12. Touch the Control Page button.
13. Prepare clean dye pots, lids and seals; the dye pots should be stamped as illustrated below. At least one dye pot should have a receptor for insertion of a temperature probe. 14. Add the necessary contents (typically dye liquor and fabric) to the dye pots and securely screw on the lids fitted with seals. Do not over-tighten the lids as this may distort the seals leading to leaks. 15. Raise the cover/covers of the appropriate baths on the Pyrotec 2000, making sure each lock engages to keep the cover raised. 16. Carefully insert each of the dye pots into the mounts, making sure they are locked in securely. Distribute the pots evenly around the dial.
17. Carefully and securely insert the temperature probe into the receptor, holding the probe by the solid metal portion. Never tug at the temperature probe while holding the lead as this may damage the lead. 18. When all the pots are securely in place, lower the cover(s) into the closed position, grasping the handle with one hand and guiding the hinge lock with the other. 19. Toggle between baths 1 and 2 by touching the red box at the top of the screen. 20. The display shows a wide range of information, including profile name, timing information, temperature, rotation speed and which stage of the profile is running. The arrow button starts the machine, or resumes the running of the machine if it has been paused.
The stop and pause buttons are self explanatory. The mute button silences the machine s alarms or warnings. Start the Pyrotec 2000 using the arrow button. 21. Upon the completion of the program the bath cover may be carefully raised, ensuring the hinge guard is locked. Be aware that the dye pots and/or bath surfaces may be hot. 22. Carefully remove the temperature probe from the dye pot s receptor, holding the solid metal portion of the probe and not just the lead. 23. Gently remove the dye pots from the mounts, pressing the tabs to allow them to slide out easily. 24. When releasing the lids from the dye pots hold them over a sink and point the open/lidded end away from the body and away from other people in the laboratory. 25. Turn off the Pyrotec 2000 using the main switch on the right side of the machine. In case of emergency Open the cover to the dye tubes if possible to stop rotation. Switch off the pyrotec on the machine and at the isolator where possible. Maintenance and Troubleshooting: These machines are calibrated every year by Roaches for performance of the temperature control side, because it is part of a total pressure system. The dye tubes are all inspected yearly by Zurich insurance as part of the pressure regulations. See Instructions Manual kept by Les Johnson.