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SAIL-RA-CMS-001
3SAE Combiner Manufacturing System (CMS) - Fibre Optic Glass Processing
Status: Draft Version 1.0 Issued: January 2026 📄 Download PDF
Safe Work Procedure - 3SAE CMS Manufacturer Documentation
RISK ASSESSMENT

⚠️ CRITICAL SAFETY INFORMATION ⚠️

CRITICAL SAFETY WARNING - HIGH TEMPERATURE PLASMA SYSTEM

The 3SAE CMS utilises thermally stabilised plasma technology that operates at temperatures exceeding 3000°C. This system presents extreme thermal hazards, high-pressure gas hazards, electrical hazards, and optical radiation risks.

NEVER disable safety interlocks or protective systems. NEVER operate without appropriate thermal and eye protection. NEVER leave the system unattended during operation. NEVER attempt to touch or inspect components during or immediately after plasma operation.

Activity, Process, or Equipment Name

3SAE Combiner Manufacturing System (CMS) - Fibre Optic Glass Processing System

Reference Number: SAIL-RA-CMS-001

Purpose/use:

Location: 218G SAIL Nexus Lab

Persons at risk:

Risk assessment team (who was consulted?):

List of Legislation, Code of Practice, Australian Standards, Guidance Materials

Risk Assessment Methodology

Assessing the risk is a brainstorming exercise, which is most effectively carried out in a team environment with the people required to complete the activity or process. Most activities or processes are broken down into a variety of separate tasks. For each task, consider the hazards, the potential harm or negative outcomes and the conditions required for those negative outcomes to occur.

Whenever assessing the health and safety risks associated with a task, always consider the following primary risk factors:

The information gathered from the risk assessment process must be used to develop a Safe Work Procedure (SWP) or clinical protocol for the activity.

Hazard Assessment Table

Task 1: High-Temperature Plasma Operation (Ring of Fire® Technology)

Hazard/s: Thermally Stabilised Plasma operating at temperatures from 300°C to >3000°C for fusion splicing, tapering, and glass processing operations.

Associated harm:

Existing Risk Controls:

Current risk rating: Medium

Additional controls required:

Residual risk rating: Low

Task 2: Compressed Air System Operation

Hazard/s: High-pressure compressed air system operating at 6.2 bar (90 psi) with flow rate of 126 L/min (~4.5 cfm).

Associated harm:

Existing Risk Controls:

Current risk rating: Medium

Additional controls required:

Residual risk rating: Low

Task 3: Electrical Hazards

Hazard/s: Dual 24V 200W power supplies and electrical components within the system including electrode power systems, vision systems, and control electronics.

Associated harm:

Existing Risk Controls:

Current risk rating: Medium

Additional controls required:

Residual risk rating: Low

Task 4: Optical Radiation and Vision System Hazards

Hazard/s: Intense visible and infrared radiation from plasma, bright illumination from vision system, and direct viewing of molten glass during processing.

Associated harm:

Existing Risk Controls:

Current risk rating: Medium

Additional controls required:

Residual risk rating: Low

Task 5: Sharp Objects and Glass Fibre Handling

Hazard/s: Handling of optical fibres, cleaved glass ends, diamond-tipped ultrasonic cleaving blade, broken or scrap fibres, and sharp glass edges.

Associated harm:

Existing Risk Controls:

Current risk rating: Medium

Additional controls required:

Residual risk rating: Low

Task 6: Vacuum System Operation

Hazard/s: Partial vacuum operation capability for adiabatic tapering and specialised processing modes.

Associated harm:

Existing Risk Controls:

Current risk rating: Medium

Additional controls required:

Residual risk rating: Low

Task 7: Chemical Hazards from Electrodes and Processing

Hazard/s: Electrode materials, potential contamination from electrode wear, cleaning chemicals for electrode maintenance, and any chemicals used in fibre preparation or cleaning.

Associated harm:

Existing Risk Controls:

Current risk rating: Low

Additional controls required:

Residual risk rating: Very Low

Task 8: Ergonomic and Musculoskeletal Hazards

Hazard/s: Prolonged seated work at computer monitor, repetitive precise movements, sustained awkward postures during fibre alignment and loading, and extended periods of concentration.

Associated harm:

Existing Risk Controls:

Current risk rating: Low

Additional controls required:

Residual risk rating: Very Low

Task 9: Training and Competency Requirements

Hazard/s: Operation of complex, high-hazard equipment by inadequately trained or supervised personnel.

Associated harm:

Existing Risk Controls:

Current risk rating: High (for untrained users)

Additional controls required:

Residual risk rating: Low (for trained and authorised users)

Task 10: Software and Control System Hazards

Hazard/s: Software malfunctions, incorrect programming of tapering or splicing processes, control system failures, and human-computer interface errors.

Associated harm:

Existing Risk Controls:

Current risk rating: Medium

Additional controls required:

Residual risk rating: Low

Task 11: General Laboratory Safety and Housekeeping

Hazard/s: Cluttered work area, spills, trip hazards from cables and air lines, inadequate lighting, poor ventilation, and general laboratory hazards.

Associated harm:

Existing Risk Controls:

Current risk rating: Low

Additional controls required:

Residual risk rating: Very Low

Implementation of Additional Risk Controls

Additional controls needed Resources required Responsible person Date of implementation RiskWare Reference
Manufacturer training completion Training course booking, travel costs if off-site Laboratory Manager Prior to equipment use N/A
Competency assessment program Assessment tools, time for practical evaluation Supervisor/Trainer Prior to equipment use N/A
Authorised users list creation and display Signage, documentation system Laboratory Manager Prior to equipment use N/A
RCD installation on power supply Qualified electrician, RCD unit Facilities/Safety Officer Prior to equipment use N/A
Annual electrical safety inspection schedule Qualified electrician, budget allocation Laboratory Manager Within 12 months of installation N/A
Thermal inspection camera procurement Budget for camera purchase Laboratory Manager Prior to first use N/A
Sharps disposal containers Appropriate containers, waste contract Laboratory Manager Prior to equipment use N/A
SDS collection for all chemicals Contact manufacturers, file system Laboratory Staff Prior to equipment use N/A
Ergonomic workstation setup Adjustable chair, assessment tool OH&S Coordinator Prior to regular use N/A
Emergency shutdown procedure signage Sign design and printing Safety Officer Prior to equipment use N/A
Exclusion zone markings Floor tape, warning signs Laboratory Staff Prior to equipment use N/A
First aid kit with splinter removal tools First aid supplies First Aid Officer Prior to equipment use N/A
Vacuum system inspection procedure Procedure documentation Laboratory Manager Prior to vacuum operation N/A
Compressed air line inspection schedule Inspection checklist Laboratory Manager Prior to equipment use N/A
Software validation and backup procedures IT support, documentation IT/Laboratory Manager Prior to equipment use N/A

List Emergency Controls

Emergency Shutdown:

  1. Press EMERGENCY STOP button (location to be identified on equipment and documented in SWP)
  2. Close compressed air supply using emergency shut-off valve
  3. If emergency stop fails: Switch off power at mains isolator
  4. Do NOT attempt to restart until:
    • Emergency condition has been fully resolved
    • Equipment has been inspected by competent person
    • Supervisor has authorised restart
    • Any necessary repairs have been completed

Do not restart if:

Fire Emergency:

  1. Activate emergency stop to shut down all systems
  2. Close compressed air supply immediately
  3. If fire is small and contained:
    • Use appropriate fire extinguisher (CO₂ or dry powder for electrical fires)
    • Ensure you have clear escape route
    • Do not fight fire if it threatens your safety
  4. If fire is spreading or involves stored compressed gases:
    • Evacuate area immediately
    • Activate building fire alarm
    • Call 000 (Emergency Services)
    • Evacuate to assembly point
  5. After fire is extinguished:
    • Do not re-enter area until declared safe by emergency services
    • Equipment must be inspected before any restart attempt
    • Complete incident report

Thermal Burn Injury:

  1. Immediately cool affected area under running cold water for at least 20 minutes
  2. Remove jewellery or constricting items before swelling occurs
  3. Do NOT apply ice, ointments, or home remedies
  4. Cover burn with sterile non-stick dressing after cooling
  5. Seek immediate medical attention for:
    • Burns larger than a 20-cent coin
    • Burns to face, hands, feet, genitals, or major joints
    • Full thickness burns (white, waxy, or charred appearance)
    • Any burn causing severe pain or blistering
  6. For chemical burns: Flush with copious water and seek immediate medical attention
  7. Complete incident report and inform supervisor

Electric Shock:

  1. Do NOT touch the person if they are still in contact with electrical source
  2. Switch off power at mains or remove person using non-conductive material (dry wood, plastic)
  3. Call 000 immediately if person is unconscious or not breathing
  4. If trained in CPR, commence if required
  5. If conscious but shocked: Have person lie down and stay still
  6. Treat any burns as per thermal burn procedure above
  7. Seek medical attention for all electric shock incidents
  8. Equipment must be tagged out and inspected before any restart
  9. Complete incident report

Glass Injury (Cuts or Embedded Fragments):

  1. Do NOT attempt to remove embedded glass - seek medical attention
  2. For minor cuts:
    • Clean wound gently with clean water
    • Apply sterile dressing
    • Seek medical attention if bleeding does not stop
  3. For eye injuries:
    • Do NOT rub eye
    • Do NOT attempt to remove any object from eye
    • Cover eye with sterile dressing without pressure
    • Seek immediate medical attention
  4. For deep cuts or significant bleeding:
    • Apply direct pressure with clean cloth
    • Elevate injured area if possible
    • Call 000 if bleeding is severe
  5. All glass injuries must be reported to supervisor
  6. Complete incident report

Compressed Air System Failure:

  1. Activate emergency stop
  2. Close compressed air supply at emergency shut-off valve
  3. Evacuate area if loud hissing or visible air leaks present
  4. Do NOT approach failed air lines or fittings
  5. If injury from air blast:
    • Move to safe area
    • Seek immediate medical attention for suspected air embolism (chest pain, difficulty breathing, confusion)
    • Treat any projectile injuries
  6. Lock out and tag equipment
  7. Contact maintenance for pressure system inspection
  8. Complete incident report

Vacuum System Failure:

  1. Activate emergency stop
  2. Vent vacuum chamber using controlled venting procedure (if safe to do so)
  3. If catastrophic failure (implosion or explosion):
    • Evacuate area immediately
    • Call emergency services if injuries present
    • Do not re-enter until area declared safe
  4. If rapid inrush of air:
    • Check for injuries from flying debris or noise trauma
    • Seek medical attention as required
  5. Lock out and tag equipment
  6. Complete incident report
  7. Equipment must be inspected by qualified technician before any restart

Software/Control System Failure:

  1. Attempt emergency stop via software interface
  2. If software unresponsive: Use physical emergency stop button
  3. If both fail: Switch off power at mains
  4. Record error messages or system state if safe to do so
  5. Do NOT attempt to restart until IT/technical support has assessed
  6. Lock out and tag equipment
  7. Complete incident report
  8. Contact manufacturer technical support for software issues

Emergency Contacts:

REVIEW

Scheduled review date 1 year 2 years 3 years
Are control measures in place (YES/NO)      
Are controls eliminating or minimising the risk (YES/NO)      
Are there any new problems with the risk (YES/NO)      
Reviewed by:      
Actual Review date:      

Risk Matrix

Likelihood Levels

Consequence Levels

Risk Rating Matrix

  Insignificant Minor Moderate Major Severe
Almost Certain Medium High Very High Very High Very High
Likely Low Medium High Very High Very High
Possible Low Medium Medium High Very High
Unlikely Very Low Low Medium Medium High
Rare Very Low Very Low Low Medium High

Risk Control Actions

End of Risk Assessment

Document Control:

Related Documents

Document Control

Version Date Author Changes
1.0 January 2026 Chris Betters Initial release