intro to lab safety handout

8/9/2019 Intro to Lab Safety Handout

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INTRODUCTION TO LAB

SAFETY

A part of 30hrs Lab Safety Training

PI-HSE75HSE or 75473

Learning ObjectivesRecognize standards, legal requirements and ADNOC COPs relevant to lab safety

Outline the causes for accidents

List and describe the classes/types of laboratories

Explain the importance of reporting near misses and hazardous conditions

Discuss the need for conducting a risk assessment of laboratory work

Learn from accidents reviewed at other & PI laboratories
http://www.pi.ac.ae/index.php


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THE PETROLEUM INSTITUTE HSE DEPARTMENT

30 Hrs LAB SAFETY TRAINING

INTRODUCTION TO LAB SAFETY - Handout

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Slide 1

The Petroleum Institute

30-hr Lab Safety Training

Topic 1: Introduction to Lab Safety

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Slide 2Attendees will be able to:

Recognize standards, legal requirements and ADNOC COPsrelevant to lab safety

Outline the causes for accidents

List and describe the classes/types of laboratories

Explain the importance of reporting near misses and hazardousconditions

Discuss the need for conducting a risk assessment of laboratorywork

Learn from accidents reviewed at other & PI laboratories

Learning Objective

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Slide 3

Lack of understanding of hazards

Improper or unintended use of equipment or reagents

Inexperienced / Over experienced Staff

Distractions, lack/loss of attention to task

Broken, damaged/improperly maintained equipment

Inadequate training and indoctrination

Lack of accountability None or inadequate risk assessment

Causes of Lab I ncidents

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Slide 4 Accident Ratio Study

1

10

60

600

Serious IncidentIncludes recordable and disabling Injuries

Minor InjuriesAny reported injury less than a recordable

Property Damage & IncidentsAll Types, including environmental releases

Incidents with no visibleInjury or Damage(Critical Incidents -Near Misses)

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Slide 5

Ensuring all employees are told to report near missincidents.

Positively reinforcing each other when reporting nearmiss incidents.

Reminding ourselves of its importance.

Sharing successes--improved work environment acrossthe entire university.

Using the incident investigation form (see PI website).

Make employees aware of the r eporting process.

Encourage Reporting of Near Miss Incidents by

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Slide 6

Learning from Incidents requires:

Know what happened - register facts for communication andcause analysis

Know why it happened - carry out cause analysis

Know why the consequences were what they were -evaluate post event actions

Know what to do - so it won't happen again

Carry out remedial actions - make sure they will be done welland on time; assign responsibilities

Let others know - communicate and report so they will learnas well

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Slide 7 29 CFR 1910.1450: OSHAOccupational Exposures to Hazardous

Chemicals in Laboratories http://www.osha.gov/

ANSI/ISEA Z358.1Emergency Eyewash and Shower Equipmenthttp://ansi.org/

ANSI/AIHAAmerican National Standard Z9.5 for LaboratoryVentilationhttp://ansi.org/

National Institutes of Health (NIH)Guidelines for the Laboratory useof Chemical Carcinogens, Pub. No. 81-2385 http://www.nih.gov/

National Fire Protection Association ( NFPA)30Flammable andCombustible Liquids Code www.nfpa.org

NFPA45Fire Protection for Laboratories using Chemical www.nfpa.org

US Environmental Protection Agency (EPA)-40 CFRPart 262Subpart K- Standards for managing hazardous waste in academiclaboratorieswww.epa.gov

Compressed Gas Association CGA- safety standards and safepractices in the industrial gas cylinder industry http://www.cganet.com/

Codes and Standards

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Slide 8 The Occupational Safety and Healths (OSHAs)Requirements

Because you work with chemicals in a laboratory, OSHArequires that you be familiar with:

The contents of the Chemical Hygiene Plan (CHP)

The location and use of MSDS for all chemicals in yourwork area

The management and proper disposal of hazardouswastes that you generate

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Slide 9 Federal & Abu Dhabi Emirate Legal Requireme nts

Environmental Legislations

Federal Law No. 24 of 1999 Protection & Development of the Environment forUAE

Local Law No. 16,2005 Concerning the Re-organization of theEnvironment Agency-Abu Dhabi & Requirementsto assess environmental impactsof sewage,hazardous waste management.

Local law No.21,2005 Waste Management in the emirate of Abu Dhabi

Federal law No.1,2002 Regulation and Control of the Use of RadioactiveSources and Protection against its Hazards

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Slide 10 Federal & Abu Dhabi Emirate Legal Requireme nts

Health & Safety Legislations

Federal Law No.8 of 1980(Chapter-

5)

Occupational Safety, PreventiveHealth & Socialcare

Federal Law No. 1,2002 Regulation and control of the use of Radioactive

Sources& Protection against its Hazards (Article-9)

Ministerial Order No.32,1982

Determination of Preventive Methods& Measuresfor the Protection of Workers from the Risk of Work

(Issued byMOL)

Ministerial Decrees 55/2004 Basic Regulation for Protection against IonizingRadiation

Ministerial Decrees 57/2004 Regarding Regulationfor Radioactive WasteManagement

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Slide 11 ADNOC COPsCOP Ref. NO Document Title

ADNOC-COPV5-03Risk Assessment & Quantitative Risk

Assessment (QRA)

ADNOC-COPV5-06HSE Risk Management

ADNOC-COPV1-11 ADNOC HSE Audit Programme

ADNOC-COPV1-02 HSEIA Requirements

ADNOC-COPV1-09ADNOC HSE Management System

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Slide 12

According to National Institute of Building Sciences(NIBS),U.S .,

The amount and type of chemicals will determine the buildingclassification.

The following are the four laboratory classes, with the special practicesassociated with each:

1. Low Risk

2. Moderate Risk

3. Substantial Risk

4. High Risk

www.wbdg.org/resources/secure_safelab.php

Laboratory Classifications

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Slide 13

Low Risk There are no special practices associated

with a low-risk laboratory.

Moderate Risk Work with materials with safety and health

ratings of 3 or greater in any categorymustbeperformedin a fumehood.

Work with substantial amounts of materialswi th hazar d r ati ngs of 1 or 2 m ust bep er fo rmed in a h oo d or in a n a ssemblydesigned tobe safein theeventof a failure.

Appropriate personal protective equipment,such as goggles, must be worn in the work

area.


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Slide 14

Substantial and High Risk

Specific policies, depending on the nature of the hazard, must be madepart of the laboratory industrial and hygiene plan as well as the safetyplan.

All work that can be completed separately from the laboratoryoperations should be completed in a separate area of the lab or i n aroom adjacent to the lab. All paperwork should be performed outsidethe lab.

No safety feature should be altered in any way without written approval.

Personal safety equipment must be worn.

A laboratory safety committee should review each new experimentplanned to determine whether it can be carried out safely (riskassessment)


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Slide 15

Accidents - "errors", "mistakes", "omissions","oversights", etc. - are opportunities to learnfrom and to take steps to make sure that thesame or similar will not happen again.

Learning From Accidents

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Slide 16 Bhopal India gas leak 1984Courtesy: http://www.filtersfast.com/Worst-Man-Made-Environmental-Disasters.asp

Thishas beencalledthe world'sworst catastrophe.OnDecember2-3, 1984,methylisocyanitegas leakedfroma pesticideplantin Bhopal,nearMadhyaPradesh inIndia,resultingin theexposureof over500,000people.Twenty -thousand deaths s ince the leak can beattributedto theaccident,which killed3,000people inafewdays and is l inked tohundreds o fthousandso fillnessessince.

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Slide 17 BP Texas City refinery explosion, 2005Courtesy: http://www.telegraph.co.uk/finance/newsbysector/energy/oilandgas/7941750/BP-caves-in-

over-record-50m-fine-for-Texas-safety-failings.htmlhttp://www.youtube.com/watch?v=VCcN4SQkb9A

OnMarch23,2005,a fireandexplosionoccurredatBP'sTexasCityRefineryinTexasCity,Texas,killing15 workersandinjuringmorethan170others.BP waschargedwith criminalviolationsof federalenvironmentallaws,andhas beensubjectto lawsuitsfromthe victim'sfamilies.TheOccupationalSafety andHealth AdministrationslappedBP witha then-recordfine forhundreds ofsafety violations, andsubsequentlyimposedanevenlarger fineafterclaimingthat BPhad failedtoimplementsafety improvementsfollowingthe disaster.

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Slide 18 BP again Deepwater Horizon 2010The explosion killed 11 men working on the platform and injured 17 others. OnJuly 15, 2010, the leak was stopped by capping the gushing wellhead, after it

had released about 4.9 million barrels (780,000 m3) of crude oil.

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Slide 19

Blowout Aftermath

SlideCourtesy: Dr. JohnWilliams

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Slide 20 Learning From Accidents(Other Universities)

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Slide 21 There were nearly 10,000 accidents in research

laboratories in 2005 injuring nearly 2 out ofevery 100 researchers, according to U.Sgovernment statistics. These accidents wereOSHA Recordable & nearly one-half of theaccidents resulted in days away from work orrestricted work duties

The rate of lab accidents at schools andcolleges is up to 100 times that in the chemicalindustry. It's 100 to 500 times greater than inplaces like Dow and DuPont, (James Kaufman, President,

Laboratory Safety Institute)

Lab Accident Statistics

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Slide 22 Lab Accident Statistics (2009)-Iowa State University

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Slide 23 Lab Accident Statistics (2009) Iowa State University

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Slide 24

June 29,2010 : One person is in the hospitalafter a hydrogen gas blast destroyed aUniversity of Missouri Biochemistry lab

During an experiment with bacteria inhydrogen-rich environments, lab personnelturned on the hydrogen supply to an anaerobichood and left the gas on. Once the gasreached an ignition source, it exploded according to Fire Dept.

The explosion "is believed to have beencaused by a spontaneous combustion ofgases including hydrogen and nitrogen thatwere being used in a research ex periment,according to university officials

The injured researchers included one graduatestudent, two postdoctoral researchers, and astaff research scientist

Research Lab Explosion Injures Four People University of Missouri

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Slide 25

June 2,2010

An undergraduate student working in chemistry lab hadbeen using hexane to clean oil from vacuum pumps. Whenthe student returned from lunch, he found that some of thesolvent had leaked onto a counter top. Before he couldclean it up, an ignition source ignited the solvent vapor.

University estimates the building repairs at $750,000 andthe cost to repair or replace equipmentincluding lasersand a nuclear magnetic resonance spectrometerat$500,000, and complete repairs could take until the end ofthe year.

Fire in Science Building Southern Illinois University

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Slide 26 April 8,2005

Students were helping to unload a shipmentof hexane into a solvent storage cabinet

"I loaded 12 bottles, and as I put the 12thbottle up, the shelf collapsed.

"This has happened before," he continues,"and it's not something where you get tooalarmed. I was more concerned aboutbreathing the vapors, and I noticed I had asmall cut on my arm. Wi thin five minutes,the explosion occurred.

Explosion and Fire in Chemistry Lab Ohio State University

Destroyed lab after the explosion and

fire

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Slide 27 The explosion could have been triggered by any

number of ignition sources including staticelectricity or a spark from a motor or switch.

One preventive solution, might be to outfit the labswith an emergency power-off switch so that allelectricity can be killed in a lab whenever there is asolvent or other flammable liquids spill.

The solvent storage cabinet although properlyvented, it was close to a freezer and probablyshould not have been.

With routine inspections somebody might havespotted the unstable shelves

A collapsed shelf in a

solvent storage cabinet is

implicated in the fire

incident.

Explosion and Fire in Chemistry Lab Ohio State University (contd.)

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Slide 28

Jan 7, 2010

Graduate student Preston Brown wasworking with another graduate student tosynthesize and characterize an energetic

material, most likely nickel hydrazineperchlorate.

Despite being told by their chemistryprofessor not to make more than 100 mgof the material, the students synthesized10 g.

Texas Tech University (TTU) Explosion

REPERCUSSION: The blast thatinjured Brown also damaged the lab

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Slide 29

Because the product was lumpy,Brown believed that the compoundwas safe when wet, so he addedsome hexane & used a pestle to tryto break up the chunks

When Brown thought he was done,he set down the mortar and took offhis goggles. Then he decided to givethe compound one last stir. Themortar exploded in Browns hands.

Texas Tech University (TTU) Explosion (contd.)

EXPLOSIVE :The purple compound madeby the students was likelynickel

hydrazine perchlorate

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Slide 30 Prof. Jaworowskiused a 2 MeV Van de Graff

generator in a particle accelerator in the physicslaboratory.

When the generator was moved to a new location,various safety features were disabledduring packing,and were notenabled at the destination.

Jaworowskicontinued to use the generator at its newlocation, although he knew that not only were thesafety features disabled, but also the radiation safetycommittee at the university had notauthorized theuse of the generator at its new location.

Jaworowskiaccidentally placed his hand in theparticle beam, and received a massive dose ofradiation that required a partial amputation of hishand

Radiation Exposure Incident(2005) Wright State University

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Slide 31 Glimpse of Past Lab Accidents

Name Year University Reason

Dr. NanajBhamare

2 011 E dg ewoo dlaboratory AberdeenProving Ground

Killed from an explosion

MichelleDufault

2011Yale University,Chemistry Dept

Working alone, she was strangledwhen her hair caught in a lathe.

Nilamma 2011 Mysore, India. Alcohol fire

S her i S an gj i 2 00 9 Unive rs it y o fCalifornia, Los

Angles.

Wasn't wearing the requiredflame-resistant lab coat and diedfrom burns after a chemical(T-butyllithiumpyrophoric) fire ignitedher sweater.

Jason Siddell 2008New Jersey 24-year-old chemist died after

being exposed totrimethylsilydiazomethane

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Slide 32 Glimpse of Past Lab Accidents (contd.)


Richard Folaron 2009 DuPont facility,Tonawanda, NY

Killed in explosion

Roland Daigle 2008Windsor, NovaScotia, SepracorPharmaceutical,

Poisoning,Trimethylsilydiazomethane. Daigle is the second chemist todie in a 12-month period afterexposure to the chemical

Parish Ashley,Charles BolchozRobert Gallagher& Karey Henry

2007T2 ,Laboratoriesin Jacksonville,Florida

Explosion

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Slide 33 Glimpse of Past Lab Accidents (contd.)


DominiqueBurget 2006

France, NationalInst. of HigherLearning inChemistry,

Ethane explosion

Tar un K. Mal 2005Cleveland StateUniversity,

Electrocution

Scott Spjut 2003, Rochester, NY, Industrial lab explosion

Unknown2001

Wroclaw, Poland, Professor killed in explosion

Unknown 1999,Scotland, Nitrogen suffocation

Unknown 1999,Edmonton,Canada, AgatLaboratories

Toluene inhalation death

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Slide 34

INCIDENT INVESTIGATION REPORT

Autoclave Explosion Incident at PI

Location : Lab 8230, Arzanah

Building

Date of the incident : 12th April, 2012

Time of the incident : 14:10 Hrs.

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Slide 35 ___________________________________

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Slide 36 ___________________________________

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Slide 37 ___________________________________

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Slide 38 ___________________________________

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Slide 39 ___________________________________

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Slide 40Summary

Thursday, April 12th, 2012, at around 14:10 Hrs.

Autoclave exploded while conducting experiment -Autoclave Assisted Thermal

Decomposition of Ammonium Tetrathiomolybdate and Carbon Nano Tube (CNT)Impregnation.

Laboratory 8230 @ Arzanah Building at PI.

No injuries.

Significant damage to autoclave, fume hood and furnace.

Potential to cause catastrophic injuries.

Detailed investigation initiated by PI HSE.

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Slide 41 Sequence of Events Experimentstarted byLab Engineer -

TwoTeflon-linedr eactionautoclaves (125 ml capacityeach)were usedin the

experiment.

Reactants inthe first autoclave:33 mgof Ammonium Tetrathiomolybdate(ATM),

100 mgofCarbonNano Tube (CNT)and 65 cm3 ofwater.

Reactants inthe secondautoclave:33 mgof ATM, 100 mgof CNTand65 cm3 of

Dimethyl Sulphoxide(DMSO).

Bothautoclaves were placedin, and heated, ina benchtop furnace.

Rate ofincrease intemperature ofthe furnace was setat5 0C per minute, to attaina

final steadystate of3000 C. The experiment was to runfor 72 hrs.

12:00noon

observedthe temperature in the furnace reached3000C.13:00Hrs

Fellowresearcher ( )working ona separate experimentin the vicinityof thisexperimental setup, leftthe lab(8-230) tohelp another researcher inthe adjacentlab.

14:00Hrs

Explosionoccurred. Uponhearingthe explosion, (whowas outside the labatthe time) respondedto the incidentand cutoff power supplyto the labvia theemergencypower shutoff switchlocatedat the entrance tothe lab.

14:10Hrs

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Slide 42

HSE was notifiedby .14:15Hrs

HSE reachedthe labto evaluate the situation. As aninitial measure all gas cylinder were shutoffand all experiments thatwere in

progress were shutdown. Fume hoodinvolvedinthe incidentwas allowedto runto ventanytoxic or

flammable chemicals thatmay have still beenpresent. Lab(8-230)was securedto restrictanyfurther work inthe lab until further notice

andapproval fromHSE.

14:20Hrs

Dr. SaeedAlhassan, Assistantprofessor, Chemical Engineeringjoined the researchgroupfor preliminaryinvestigation.

14:30Hrs

Labwas re-visitedbyHSE as part ofthe data collectionphase ofthe investigation.16:45Hrs

Sequence of Events (continued.)

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Slide 43Observations and Analysis

Based on the following categories:

Equipment Factor

Personal Factor

Chemical Chemistry Factor

Job factor

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Slide 44 Equipment Factor

The autoclave (Model No 4750 pressurevessel: capacity 125 ml; Maximum Pressure- 3000 psi (200 bars); Max temp: 3500 C )

used in the experiment is from ParrInstrument Company, which was supplied byBusiness Communications LLC to PI (PIPurchase order dated: 28 Nov-2010).

The autoclave was used brand new afterpurchase.

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Slide 45

As per the PI purchase order# 100250, the autoclave was purchased

without a pressure relief device and was used in the experiment without apressure relief device.

The manufacturers (Parr Instruments) operating instructions

manual (#230 M) titled: Safety in the operation of laboratoryreactors and pressure vessels carries the following note: Allstandard Parr pressure vessels are provided with either a suitablerelief device or a means to attach one (typically in the form of a

plugged opening). When a pressure vessel is delivered without apressure venting device, it is the customers responsibility to

provide pressure relief in order to protect the operator & theequipment from destructive high pressure (page- 3).

Equipment Factor -1

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Slide 46

This experiment was carried out i n a general purpose fume hood withoutany barricades to protect against explosion.

Parr Instruments document #230 M, mentions the following:Certain explosive reactions proceed with such speed that theshock wave created by the explosion may damage the v essel

before the rupture disc can dump the excess pressure. The best

protection against the hazard is to operate the reactor behind asuitable barricade or in a pressure test cubicle or cell.

Equipment Factor - 2

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Slide 47

This experiment was set for operation at 3000 C.

Parr Instruments literature on polymer liners (document #314)

states the following: TFE polymer liners will s ignificantly alter theheat transfer characteristics of a reactor and may necessitate theuse of other temperature measurement and control methods to

protect the liner and the reactor from overheating. Therecommended maximum operating temperature for these TFEliners in 2500 C.

Equipment Factor - 3

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Slide 48Chemical/Chemistry Factor

Parr Instruments document #230 M mentions: Since safety in benchscale pressure reactions is so closely related to the chemistry involvedin the process, there are several basic questions that the operator must

always consider before starting to use the pressure equipment:

Is the reaction exothermic?

What By-products will be produced & what will be their be havior?

What maximum temperature & pressure limits will be observed?

Under what circumstances (temperature, pressure & catalyzing

agents) might the reaction run out of control?

By considering these and any other related safety questions before

starting a pressure operation, the user should be able to anticipate any

violent chemical behavior & take steps to prevent it

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Slide 49Chemical/Chemistry Factor

Dimethyl Sulfoxide(DMSO) solvent Flash point 870 C;

Boiling point-1890 C &

Auto ignition temperature 2150 C

Thermally unstable, especially in the presence of other materials. Quantity used exceeded the normal amounts used in autoclaves of

such size.

Heating above its decomposition temperature in the presence of anammonia generating compound caused the violent reaction thatlead to a surge in temperature/pressure.

MSDS (material safety data sheets) of the chemicals(AMT, DMSO, MoS2 etc.) were not referred to.

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Slide 50Job Factor

PIs HSE Policy and Procedure # PIP 10012 on Risk

Assessment was not followed.

Approved SOP and risk assessment were not available.

Experiment was not conducted in accordance with thedepartments internal procedure (notifying and seeking

approval from the departments HSE committee).

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Slide 51Other Observations

It was fortunate that no one was present in the lab at the time ofexplosion. Or else, serious injuries could have occurred.

Manufacturers literature mentions that Ear protection is also recommendedsince the loud report produced by bursting rupture disc may damage the hearing of anyone

standing near the reactor. Neither nor who was working in vicinityof the experiment was wearing hearing protection. It wasfortunate however, as mentioned above, that none of them werepresent in the lab at the time of the incident.

Experiment was carried out in a fume hood that was notapproved for the purpose, BUT this reduced the impact of theexplosion on other equipment in the lab.

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Slide 55

Before you do an experiment, demonstrationor activity...

KNOW the hazards.

KNOW the worst credible thing that could happen.

KNOW what to do and how to do it if they shouldhappen.

KNOW and use the prudent practices, protectivefacilities, and protective equipment needed to

minimize the risks.

In other words, conduct a risk assessment of your work

PI Policy

Summary

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Slide 56

Presentation by:TeamHSE

ThePetroleum Institute

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intro to lab safety handout

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