systematic identification and reduction of laboratory hazards · identification and reduction of...
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Systematic Identification and
Reduction of Laboratory Hazards
This presentation compiled by Burton “Billy” Schmuck of the Gene and Linda Voiland School of Chemical Engineering and Bioengineering
Purpose of Training
• Teach you tools to help you think: Why you deal with hazards proactively Identify hazards that may exist What may go wrong around that hazard How to deal with the hazards How to respond when things go wrong
• This training does not: Cover in depth training on any specific hazard topic Train you on lab/equipment specific items Authorize you to perform tasks or access restricted locations
Why Have a Robust Safety Program?
We impact people with real livesand the world we live in
• Employees• Associates• Community• Environment
Images © 2013 Portrait Innovations
Safety and Business – Obvious Costs
Source: 2012 E. I. du Pont de Nemours and Company – Bradley Curve Infographic
• Direct costs• Medical costs• Wages• Claims administration
• Indirect Costs (>5x direct costs)• Damaged items• Lost production/quality• Replacement
labor/efficiency• General liabilities• Litigation
Safety and Excellence
Source: 2012 E. I. du Pont de Nemours and Company – Bradley Curve Infographic
Cost Avoided
Business Excellence
Business Excellence Gained• Capable leadership• Improved morale• Increased productivity• Organizational resilience
• Doesn’t change with new leader
• Doesn’t change with business cycle
DirectCost
Source: 2012 E. I. du Pont de Nemours and Company – Bradley Curve Infographic
Safety and Business – Money Saved
Safety – From Instinct to Culture
Inju
ry R
ate
Source: 2012 E. I. du Pont de Nemours and Company – Bradley Curve Infographic
When building a program you can’t skip steps
Researcher ResponsibilitiesAdministration and management are responsible for enacting a safety program and for every operation and task which operates under that program
Principal Investigator (PI) or Lab Instructor (LI) are responsible for the health and safety of all lab employees PI/LI (the employer) can be held personally liable Must make “good faith effort” to implement the CHP PI/LI can delegate their safety duties, but they must ensure that
they are performed
Note: as the 2009 UCLA lab fatality showed, the PI can go to prison and the university can face criminal charges for failure to train, supervise, or provide PPE.
How to Control Hazards• Identify the hazards
• Control the hazards
• Assess the hazards
• Write the procedure
• Systematically review
Plan
DoCheck
Act
Risk Management System
ContinuousImprovement
Management ResponsibilityWhich Requires
Employee Participation
Potential Hazards on the Job: Chemical• Toxins• Carcinogens• Flammables• Oxidizers• Reducers• Pyrophorics• Corrosives• Etc…
Potential Hazards on the Job: Physical
• Mechanical• Thermal• Electrical• Optical• Pressure differential
Potential Hazards on the Job: Biological• Biosafety Level 1 Generally does not cause
disease in healthy humans• Biosafety Level 2 Generally can cause disease in
healthy humans• AIDS• Hepatitis• Staph infections• Mammalian/human tissues
Human white blood cell attacking methicillin-resistant Staphylococcus aureus (MRSA). - NIH
Potential Hazards on the Job: Radiation• Ionizing radiation – has energy to damage human
tissue• Machine source: (typically x-rays) Turn on, turn off Measurement and monitoring still needed
• Material source Always on Can be physically spread or ingested
Identify Hazards• Asphyxiation/
Oxygen Displacement• Biological• Chemical (Carcinogen)• Chemical (Corrosive)• Chemical (Flammable)• Chemical (Mutagen)• Chemical (Teratogen)• Chemical (Toxic)• Dispersible Engineered
Nanomaterial• Dust/Particles (Irritant)• Explosion (Chemical
Reaction)
• Explosion (Over Pressurization)
• Electrical (Shock/Short-Circuit)
• Electrical (Fire)• Electrical (Static/ESD)• Electrical (Loss of Power)• Ergonomics (Strain)• Ergonomics (Human Factor)• Excavation (Collapse)• Fall (Slip, Trip)• Fire/Heat• Mechanical/Vibration
(Chaffing/Fatigue)• Mechanical Failure
• Noise• Radiation (Ionizing)• Radiation (Non-Ionizing)• Struck By (Mass
Acceleration)• Struck Against• Temperature Extreme (Cold)• Temperature Extreme (Heat)• Visibility• Weather
(Snow/Rain/Wind/Ice)• Etc…
Preferred Hazard Controls• Elimination Do not utilize the hazard for the task
• Substitution Use a lower risk approach for the task
• Engineering Automatic and intrinsic control Requires no human interaction
• Such as an electrical interlock
Other Hazard Controls• Administrative Standard operating procedures (SOP) Laboratory manuals Training requirements / Authorized users
• Personal protective equipment (PPE)(last line of defense) Clothing Gloves Lab coat Glasses
Evaluating HazardsTwo primary factors
• Potential severity of the hazard Based only on intrinsic controls (i.e. engineering) Policy, administrative, PPE, etc… do not apply For substances quantity/conc. is the only control
• Likelihood of occurrence or exposure Based on the probability with controls in place
Definitions: Severity• Catastrophic (4) – Death, permanent disability; system or
facility loss; lasting public health or environmental impact
• Severe (3) – Serious injury; temporary disability; subsystem loss or facility damage; temporary public health or environmental impact
• Moderate (2) – Medical treatment; lost work days; minor facility damage; external reporting cleanup requirements
• Minor (1) – First aid only; negligible or slight facility damage; routine cleanup
ANSI Z10 Definitions, we use moderate for ANSI’s marginal and minor for ANSI’s negligible
Definitions: Likelihood of Occurrence• Frequent – Likely to occur repeatedly• Probable – Likely to occur multiple but
infrequent times• Occasional – likely to occur at some time• Remote – Possible, but not likely to occur• Improbable – Very unlikely; can reasonably assume
it will not occur
Relative Hazard IndexPotential Severity of Hazard
Catastrophic Severe Moderate Minor
Like
lihoo
d of
Occ
urre
nce
or
Exp
osur
e
Frequent CriticalRHI=4
CriticalRHI=4
SeriousRHI=3
MediumRHI=2
Probable CriticalRHI=4
CriticalRHI=4
SeriousRHI=3
MediumRHI=2
Occasional CriticalRHI=4
SeriousRHI=3
MediumRHI=2
LowRHI=1
Remote SeriousRHI=3
MediumRHI=2
MediumRHI=2
LowRHI=1
Improbable MediumRHI=2
LowRHI=1
LowRHI=1
MinimalRHI=0
ANSI Z10 Definitions, we use moderate for ANSI’s marginal and Minor for ANSI’s Negligible
Example 1: Gas CylindersPotential Severity of Hazard
Catastrophic Severe Moderate Minor
Like
lihoo
d of
Occ
urre
nce
or
Exp
osur
e
Frequent CriticalRHI=4
CriticalRHI=4
SeriousRHI=3
MediumRHI=2
Probable CriticalRHI=4
CriticalRHI=4
SeriousRHI=3
MediumRHI=2
Occasional CriticalRHI=4
SeriousRHI=3
MediumRHI=2
LowRHI=1
Remote SeriousRHI=3
MediumRHI=2
MediumRHI=2
LowRHI=1
Improbable MediumRHI=2
LowRHI=1
LowRHI=1
MinimalRHI=0
Death?Permanent Disability?Building Loss?
Severity = Catastrophic
Without Admin ControlsProbability = Frequent
With Admin ControlsProbability = Occasional(clamp type brackets)
Reduce probability by policy prohibiting bench clamps?
Example 2: 120V Electrical CordPotential Severity of Hazard
Catastrophic Severe Moderate Minor
Like
lihoo
d of
Occ
urre
nce
or
Exp
osur
e
Frequent CriticalRHI=4
CriticalRHI=4
SeriousRHI=3
MediumRHI=2
Probable CriticalRHI=4
CriticalRHI=4
SeriousRHI=3
MediumRHI=2
Occasional CriticalRHI=4
SeriousRHI=3
MediumRHI=2
LowRHI=1
Remote SeriousRHI=3
MediumRHI=2
MediumRHI=2
LowRHI=1
Improbable MediumRHI=2
LowRHI=1
LowRHI=1
MinimalRHI=0
Death?Permanent Disability?Building Loss?
Severity = Catastrophic
With admin controlsProbability = remote(fire and electrocution)
Does the hazard index match your perception of risk? (serious)
Does familiarity change hazard perception?
Example 3: 1100º C Muffle FurnacePotential Severity of Hazard
Catastrophic Severe Moderate Minor
Like
lihoo
d of
Occ
urre
nce
or
Exp
osur
e
Frequent CriticalRHI=4
CriticalRHI=4
SeriousRHI=3
MediumRHI=2
Probable CriticalRHI=4
CriticalRHI=4
SeriousRHI=3
MediumRHI=2
Occasional CriticalRHI=4
SeriousRHI=3
MediumRHI=2
LowRHI=1
Remote SeriousRHI=3
MediumRHI=2
MediumRHI=2
LowRHI=1
Improbable MediumRHI=2
LowRHI=1
LowRHI=1
MinimalRHI=0
Medical Treatment?Lost Work?Minor Facility Damage?
Severity = Moderate
With admin controlsProbability = remote(for burn)
Does the hazard index match your perception of risk? (Medium)
Does familiarity change hazard perception?
Hazard Review Process• Write out your procedure• Identify every hazard• For each hazard, at each stage, ask what could go
wrong• Eliminate, substitute, engineer, administrate• After designing controls, determine the relative hazard
index (use the matrix) – if above RHI 2, redesign and/or safety committee involvement
• Make a plan for when the event goes wrong• Make note of emergency stop/shutdown procedures –
you may not be around
Hazard Communication• Signal words give immediate information about the
degree of a hazard• Pictograms illustrate the category of hazard• Hazard statements further inform of specific
hazard consequences• Precautionary statements address hazard
prevention, response, storage, or disposal
Remember: All chemical containers need sufficient labeling which is clear to non-laboratory personnel
Signal Words
! WARNING
! DANGER
! CAUTION
Notice
An imminent hazard which will result in death or serious injury unless avoided
A hazardous situation hazard which could result in death or serious injury unless avoided
A situation which might result in minor to moderate injury unless avoided
Important information which is not about a hazard to personnel. Damage to property, equipment and many other types of information may be a “Notice”
References: ANSI Z535.5 and OSHA 1910.145
Globally Harmonized System (GHS) Pictograms
Flammable
Oxidizing
Explosive
Toxic
Health
Corrosive
Compressed gas
Environmental
Irritant
GHS Statements
• Hazard Statements – standardized phrase describing the hazard such as: “H330: Fatal if inhaled”
• Precautionary Statements – standardized phrase addressing one of the following categories Prevention: “P222: Do not allow contact with air” Response: “P302+352: IF ON SKIN: Wash with soap
and water” Storage: “P403: Store in a well ventilated place” Disposal: “P501: Dispose of contents/container to…”
Standard Operating Procedures (SOP) and Hazard Assessments
• SOPs and hazard assessments are a responsibility of the PI/LI for hazardous processes/chemicals
• SOPs are can cover a process, a procedure, a single hazardous substance, or a group of similar hazards
• The hazard assessment may be incorporated into the SOP• PI/LI responsible to review work area and identify hazards• Hazard assessments determine proper PPE, engineering
controls and administrative controls• The goal of hazard assessments are to reduce/eliminate
exposures to hazards – not restrict research/learning
Standard/Safe Operating ProceduresItems to include• Procedure name, date authored, date(s) reviewed• Procedure summary, power user/primary contact• Required PPE, authorized users• Detailed outline of procedure• Contingency plans for emergency Emergency stop Emergency treatment
Template at EHS: http://ehs.wsu.edu/labsafety/manual/appendixm.html
Standard Operating Procedures (SOP) and Hazard Assessments
• SOPs and hazard assessments are a responsibility of the PI/LI for hazardous processes/chemicals
• SOPs are can cover a process, a procedure, a single hazardous substance, or a group of similar hazards
• The hazard assessment may be incorporated into the SOP• PI/LI responsible to review work area and identify hazards• Hazard assessments determine proper PPE, engineering
controls and administrative controls• The goal of hazard assessments are to reduce/eliminate
exposures to hazards – not restrict research/learning
Safety Data Sheets (SDS)• Formerly known as MSDS• Now globally harmonized• Harmonization means that any vendor will give you a form with
the same sections in the same order with the right information• Hazards are classified by quantitative objectives Class 1 acute oral toxins have a LD 50 < 5 mg/kg Class 2 acute oral toxins: LD 50 >5, <50 mg/kg, etc…
• https://www.osha.gov/dsg/hazcom/ghs.html• Employees/students must have access to them for all chemicals• Retain for 30 years or a record of what, where, and when used
(dated inventory)
Event Reporting• Report injuries
(24 hour time limit) HR Website
• Report hazards SPPM Form 2-52-2
• Report near misses
• Report near misses
• Report near misses
Event reporting allows for detailed tracking and accident prevention
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0.05
0.10
0.15
0.20
0.25
0.30
0 1 2 3 4 5 6 7 8
Prob
abili
ty F
ract
ion
Number of Hazard Notifications
Probability of Hazard Notifications Reported at the VSCEB in a Given Month
Predictions are based on a Poisson analysis of submissions received over a 447 day period
Stop Work Authority• Everyone has the responsibility to stop a process
they observe as unsafe
• Responsibilities don’t always come with authority
• It is the job of administration to be certain that every employee knows that they will be backed at the highest level of authority if work is stopped for safety review
• EHS – http://ehs.wsu.edu/ Laboratory Safety Manual Chemical Waste Pickup Chemical Hygiene Plan and other templates for laboratories
• Safety Policies and Procedures Manual (SPPM) -http://public.wsu.edu/~forms/manuals.html Covers most aspects of safety at WSU
• Safety Policies eliminate guess work, provide universal behavioral expectations, and help ensure that your neighbor won’t kill you (and visa versa)
WSU Resources
Hazard Assessment: Review• If anything can go wrong, it will go wrong – 2nd law
of thermodynamics (AKA Murphy’s Law).
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