Use this form to document Safe Work Procedures for hazardous activities and processes. The information in your Safe Work Procedure (SWP) should be supported by a risk assessment.

List the Hazards and Risk Controls as per Risk Assessment

List Resources Required

Including personal protective clothing, chemicals and equipment needed.

• PPE: safety glasses (AS/NZS 1337.1) for the demonstrator filling balloons; closed-toe shoes for all demonstrators; hat and sunscreen if the display is unshaded
• One 103 L disposable cylinder of 1% CH4 / balance N2, CAC Gas part 103DS1VCH4N (SDS No. 303), in a padded transport box
• C10-thread fixed-flow regulator for 103 L disposable cylinders (nominal 1 L/min) with on/off lever, short length of 6 mm tubing and balloon nozzle
• 30 to 50 balloons, 23 cm (9 inch) size, latex-free (chloroprene) preferred; spare balloons in a sealed bag
• SAIL fibre optic methane sensor: interrogator unit, gas cell with sample intake tube, small diaphragm sample pump, laptop with sensor software, charged batteries or power bank
• Portable RCD and one tested and tagged extension lead (only if mains is required); cable cover or gaffer tape
• Table (weighted if lightweight), table cover, lidded bin, balloon count sheet
• Printed signs: Calibration gas, 1% methane in nitrogen, non-flammable, Class 2.2; Do not inhale balloon gas; Contains latex (if applicable)
• Printed copies of SDS No. 303 and the risk assessment
• Small first aid kit, bottle of clean water or saline for eye rinse, emergency contact card (000, Security 9351 3333, supervisor mobile, event coordinator, first aid post), charged mobile phone on each demonstrator

Step by Step Instructions for Undertaking the Task

1. BEFORE STARTING - CRITICAL SAFETY REQUIREMENTS:
   - You must have completed the SAIL General Local Induction and been briefed on this RA and SWP by the supervisor
   - You must be listed as a rostered demonstrator for this event
   - You must NEVER let anyone inhale from a balloon, and you must NEVER give a balloon away
   - You must NEVER leave the cylinder with the regulator fitted and the valve open while unattended
   - You must NEVER expose the cylinder to heat, direct sun or a parked vehicle
   - You must NEVER open a fibre connector while the interrogator is switched on
2. PRE-EVENT PREPARATION (in the laboratory, the day before):
3. Check the cylinder:
   - Confirm the label reads 1% CH4 / Bal. N2, part 103DS1VCH4N, SDS 303, Class 2.2
   - Check the cylinder body for dents, corrosion or damage to the C10 valve outlet thread
   - Check the shelf-life date on the label has not passed
   - If ANY check fails: DO NOT USE, tag the cylinder and report to the supervisor
4. Test-fit the regulator:
   - With the cylinder upright, screw the C10 regulator onto the valve outlet by hand until fully seated; the thread must engage smoothly without force
   - Open the cylinder valve slowly (anticlockwise, one full turn); the regulator gauge should read approximately 70 bar (lower if partly used)
   - Close the valve and listen for leaks at the joint; if hissing is heard, close the valve, remove and re-seat the regulator
   - Operate the flow lever and confirm gas flows from the nozzle, then close it
   - Close the cylinder valve, bleed the regulator until the gauge reads zero, and remove the regulator for transport
5. Trial-fill two balloons to approximately 15 cm diameter (about 1.5 to 2 minutes each at 1 L/min). Tie off and confirm they hold gas for at least an hour. Note how many seconds gives the right size
6. Check the sensor apparatus:
   - Charge the laptop and any battery packs
   - Confirm the interrogator label laser class and that all fibre connectors are mated and the fibre run is secured
   - Run the sensor software, release a trial balloon at the intake and confirm the reading responds
   - Confirm any mains equipment carries a current test and tag label
7. Pack the kit against the resources list, including signs, SDS, RA, first aid kit and balloon count sheet
8. Brief all demonstrators (30 minutes): hazards, the balloon hand-over rule, the no-inhalation rule, emergency contacts and the location of the event first aid post
9. TRANSPORT TO THE VENUE:
10. Close the cylinder valve and confirm the regulator is removed
11. Place the cylinder upright in the padded transport box with the valve protected
12. Carry the box by hand or on a trolley. Do not place it in a backpack, do not throw or roll it, and do not leave it in a vehicle in the sun
13. On arrival, place the box in a shaded position behind the table
14. SETTING UP THE DISPLAY (MANDATORY - DO NOT SKIP):
15. Sign in with the event coordinator and record the start time and demonstrator names on the balloon count sheet
16. Position the table against the cloister wall (or under the marquee on Eastern Avenue) so the public approach from one side only. Weight the table if it is lightweight. Keep a clear 1.5 m walkway past the display
17. Set up the sensor:
    - Place the interrogator, laptop and pump at the back of the table with the fibre run taped down and out of reach
    - Route the sample intake tube to the front edge of the table where the public will release balloons
    - Use battery power. If mains is unavoidable, plug the single tested and tagged lead into the portable RCD, press the RCD TEST button and confirm it trips, reset it, and cover the connection. Run the cable along the wall under a cable cover
    - Switch on the interrogator and laptop and confirm a stable baseline reading
18. Set up the cylinder:
    - Stand the cylinder upright in its box behind the table, in shade, where it cannot be knocked over
    - Touch-check the cylinder is not warm
    - Fit the C10 regulator by hand until fully seated
    - Open the cylinder valve slowly one full turn, check the gauge, then close the valve again. Leave the valve CLOSED until filling
19. Display the signs (Non-flammable calibration gas; Do not inhale balloon gas; Contains latex if applicable) and place the SDS and RA in a folder on the table
20. Confirm emergency arrangements: each demonstrator knows the location of the event first aid post, the nearest exit and assembly point, and has the emergency contact card
21. Final check before opening:
    - Cylinder valve closed, cylinder secured and shaded
    - Cables clear of the walkway
    - First aid kit and eye rinse at the table
    - Lidded bin at the table
    - Two demonstrators present
    - If ANY check fails: DO NOT OPEN THE DISPLAY; resolve the issue or contact the supervisor
22. FILLING BALLOONS (demonstrators only):
23. Put on safety glasses and stand at the back of the table facing away from the public
24. Stretch a balloon over the regulator nozzle and hold the neck firmly
25. Open the cylinder valve one full turn
26. Operate the flow lever for the pre-timed number of seconds to reach approximately 15 cm diameter. NEVER fill beyond 15 cm; a small balloon is enough for the sensor and will not burst
27. Release the lever, pinch the neck, remove the balloon and tie it off
28. Repeat for a batch of 10 to 15 balloons, then CLOSE THE CYLINDER VALVE
29. Inspect each balloon; discard any that are weak, perished or over-stretched into the lidded bin
30. Store filled balloons in a lidded tub or tied to a weighted string behind the table (the gas does not float, but wind can move them). Record the number filled on the balloon count sheet
31. Close the cylinder valve at any time the table is unattended or filling stops for more than a few minutes
32. RUNNING THE DEMONSTRATION (public interaction):
33. ATTENDANCE REQUIREMENT: two demonstrators MUST be on the stand at all times during opening hours. One runs the sensor and hands balloons over; the other manages the queue and fills balloons
34. For each participant:
    - Hand over one balloon and say: squeeze the neck and let the gas out near this tube, like a fart; please do not breathe it in, there is no oxygen in it
    - Stay within arm’s reach while they release the gas at the intake tube
    - Point out the sensor reading rising on the laptop screen and explain the science
    - Take the balloon straight back. Balloons are NEVER given away, left on the table, or handed to a second person unsupervised
35. For children under 12: only with a parent or carer present. For young children, the demonstrator holds the balloon and lets the child squeeze it
36. If a balloon bursts: pick up every fragment immediately and bin it. Do not let children pick up fragments
37. If anyone says they have a latex allergy: offer the demonstrator-operated release, or use a latex-free balloon
38. If anyone inhales from a balloon: take it away, sit them in fresh air away from the crowd and follow the emergency procedure
39. Periodic checks every 30 minutes:
    - Cylinder valve closed and cylinder not warm
    - Balloon count (out and back) matches
    - Cables still covered and walkway clear
    - No balloon fragments on the ground
    - Sensor reading has returned to baseline between participants (if not, move the intake tube into cleaner air for a minute)
40. If it rains on the table, or wind makes the balloons or equipment unmanageable: close the valve, switch off and cover the equipment and pause the demonstration
41. PACK-DOWN:
42. Close the cylinder valve fully (clockwise)
43. Bleed the regulator by operating the flow lever until the gauge reads zero, then unscrew the regulator
44. Place the cylinder upright in its padded box
45. Deflate all remaining balloons (cut the neck) and put all balloon material in the lidded bin. Reconcile the balloon count sheet; leave NO balloon material at the venue
46. Switch off the interrogator, pump and laptop. Unplug and coil any mains lead and the RCD. Do not open fibre connectors at the venue
47. Remove all signs, tape and cable covers, leaving the heritage surfaces as found
48. Sign out with the event coordinator; note any incidents or near misses on the count sheet and report them to the supervisor
49. Transport the cylinder and equipment back to A31 P2012 in the padded box, and return the cylinder to the gas storage cabinet with the valve closed, regulator removed and label facing out

Emergency Shutdown Procedures

• USE EMERGENCY SHUTDOWN IF: the cylinder is dropped, the valve is damaged, the regulator is ejected or hissing cannot be stopped; any person is faint, unwell or injured at the display; a fire alarm or evacuation instruction is given; rain reaches electrical equipment, or there is lightning or high wind; the crowd cannot be controlled; or any other unsafe condition
• CLOSE THE CYLINDER VALVE by turning the C10 valve handwheel fully clockwise. Gas flow stops immediately. There is no emergency stop button; the valve is the shutdown
• If the valve cannot be closed (damaged or stuck open), carry the cylinder by the body to the nearest open space away from people and let it vent. A full cylinder empties in a few minutes through the regulator. The gas is non-flammable and non-toxic; keep people 3 m away only because of the pressure, not the gas
• Switch off the interrogator and laptop at their power switches; unplug the mains lead from the RCD if used
• Assess the situation: injury (first aid), fire elsewhere (evacuate), weather (cover and pause)
• Do NOT restart until the emergency is resolved, the equipment is inspected and the supervisor approves. Repeat the setting-up checks before restarting. A dropped cylinder MUST NOT be used again
• Report: record the time, date and circumstances; report to the supervisor and via RiskWare

Emergency Procedures for Fires, Spills or Exposure to Hazardous Substances

• PERSON INHALED BALLOON GAS OR FEELS FAINT:
  - Take the balloon away
  - Sit the person down in fresh air away from the crowd; stay with them
  - Light-headedness from one breath passes within a minute
  - If they faint, lose colour or do not recover within 2 minutes: call 000, then University Security on 9351 3333, and send the second demonstrator to fetch event first aid
  - If unresponsive and not breathing normally: start CPR and send for the nearest AED (event first aid post)
  - Record the incident and report via RiskWare
• CYLINDER DROPPED, VALVE DAMAGED OR REGULATOR EJECTED:
  - Move people back at least 3 m
  - If the cylinder is venting and stationary, wait for it to empty (a few minutes); do not try to catch a moving cylinder
  - When silent, pick it up, mark it DAMAGED and take it out of service
  - Treat any injury (first aid) and report to the supervisor and via RiskWare
• GAS LEAK (hissing at the regulator or valve):
  - Close the cylinder valve
  - Remove and re-seat the regulator; if the leak persists, remove the regulator and do not use the cylinder
  - There is no fire or health hazard from the leaked gas in the open air; no evacuation is required
• BALLOON FRAGMENT IN EYE OR CHOKING:
  - Eye: do not rub; rinse with clean water or saline; seek medical attention if pain or vision disturbance persists
  - Choking (child with a balloon fragment): call 000 and event first aid immediately; give back blows and chest thrusts as per first aid training
• FIRE EMERGENCY (fire elsewhere at the event):
  - Close the cylinder valve; carry the cylinder in its box with you if it can be done without delay; the gas does not feed a fire, but a cylinder heated above 50 degrees C could rupture
  - Follow the event evacuation procedure and the wardens’ directions
  - Call 000 if not already done; go to the assembly point; do not re-enter until cleared
• SEVERE WEATHER:
  - Close the cylinder valve, switch off and cover the electrical equipment
  - Move the cylinder, balloons and equipment under cover as directed by event staff
  - Resume only when conditions are safe and the supervisor agrees
• EQUIPMENT MALFUNCTION:
  - Switch off the interrogator, pump and laptop
  - Do not open the interrogator or disconnect fibres with the source on; do not attempt repairs at the venue
  - If any fibre or cable is damaged, keep the source off for the rest of the event
  - Report to the supervisor
• EMERGENCY CONTACTS:
  - Emergency services: 000
  - University of Sydney Security (24 hours, emergency): 9351 3333
  - University of Sydney Security (general): 9351 3487
  - Event first aid post: TODO: location and contact from event organiser
  - Supervisor: Chris Betters, TODO: mobile number
  - School of Physics WHS Officer: TODO: name and number
  - Event coordinator: TODO: name and number

Clean Up and Waste Disposal Requirements

• Display area: pick up all balloon fragments, tape and cable ties; wipe the table and sample intake tube (the gas leaves no residue); remove signs and leave heritage surfaces as found
• Sensor apparatus: coil cables, cap the sample intake tube, pack the interrogator and laptop in their cases; do not clean or open fibre connectors at the venue
• Balloons and fragments: deflate and place all balloon material in general waste. NEVER release balloons; balloon release is littering under the Protection of the Environment Operations Act 1997 (NSW)
• Gas mixture: residual gas may be vented to the open air or a fume cupboard; it is non-flammable and non-toxic and needs no treatment
• Empty cylinder: non-refillable, NEVER attempt to refill. To dispose: outdoors or in a fume cupboard, fit the regulator, open the valve and vent until the gauge reads zero and no flow is heard; remove the regulator, mark the cylinder EMPTY, and dispose of it through the University scrap metal or hazardous waste stream in accordance with SDS No. 303. A cylinder with gas remaining is returned to the gas storage cabinet in A31 P2012
• Maintenance: inspect the regulator O-ring and nozzle tubing before each event and replace perished parts; check the cylinder shelf-life date before each event; record cylinder use (date, event, balloons filled, approximate remaining pressure) on the cylinder log

References Used in the Development of This SWP

E.g. codes of practice.

• Work Health and Safety Act 2011 (NSW)
• Work Health and Safety Regulation 2017 (NSW), Chapter 7 Hazardous Chemicals
• Australian Code for the Transport of Dangerous Goods by Road and Rail (ADG Code), edition 7.9
• AS 4332-2004 The storage and handling of gases in cylinders
• AS/NZS 60079.10.1:2022 Explosive atmospheres, Classification of areas
• AS/NZS 2243.1:2021 and AS/NZS 2243.2:2021 Safety in laboratories
• AS/NZS 3760:2022 In-service safety inspection and testing of electrical equipment
• AS/NZS 1337.1:2010 Personal eye protection
• Safe Work Australia Code of Practice: Managing risks of hazardous chemicals in the workplace
• CAC Gas and Instrumentation quotation SQ1070 and Safety Data Sheet No. 303 (1% CH4 in N2)
• Protection of the Environment Operations Act 1997 (NSW)
• SAIL General Laboratory Risk Assessment and Safe Work Procedure (general-lab-safety)
• University of Sydney WHS Policy 2016 and event risk management requirements

Competency Required

Qualifications, certificates, licensing, training — e.g. course or instruction.

• SAIL General Local Induction completed (laboratory hazards, emergency procedures and reporting)
• Demonstration-specific briefing delivered by the supervisor before each event: properties of the 1% CH4 / N2 mixture (non-flammable at any dilution, simple asphyxiant, Class 2.2); cylinder handling (transport, shade, valve closed between fills, never heat, never refill); regulator fitting, leak check and balloon filling to 15 cm; the balloon hand-over rule and the no-inhalation rule; sensor setup, battery and RCD use, fibre connector rule; emergency procedures, contacts, first aid post and assembly point
• Working with the public: supervising children with a parent or carer present; latex allergy and choking hazard awareness; crowd management and event marshal directions
• First aid awareness: response to a person who feels faint; when to call 000 and Security; location of the first aid kit, eye rinse and event AED
• Theory assessment (oral questioning by the supervisor): why the gas cannot burn and why it is Class 2.2; what to do if someone inhales from a balloon; when the cylinder valve must be closed; the balloon hand-over rule; emergency contacts. All safety-critical questions must be answered correctly
• Practical assessment (supervised): fitting the regulator, leak check and closing the valve; filling and tying off a balloon to 15 cm; handing a balloon to a participant, supervising the release and taking it back; emergency shutdown (closing the valve, switching off equipment). Any safety-critical error requires re-briefing and reassessment
• Ongoing: briefing repeated before every event; retraining after any incident or near miss, when this SWP or the RA is updated, or if unsafe practice is observed. Briefing attendance and sign-off recorded by the supervisor; balloon count sheets and cylinder log retained

Staff Approved to Assess Competence for This SWP

Chris Betters (Senior Research Fellow, SAIL)

SWP Sign Off Sheet

SWP name and version: Public demonstration of the SAIL fibre optic methane sensor using balloons filled with 1% CH4 / balance N2 calibration gas (103 L disposable cylinder) (Version 1.0)

In signing this section the assessor agrees that the following persons are competent in following this SWP.

Competency sign-off is recorded on the printed copy of this SWP (use the Word/PDF download) or in the laboratory training register.

End of Safe Work Procedure

Related Documents

• Risk Assessment - Hazard identification and controls

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