Systematic Identification and Reduction of Laboratory Hazards

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Ezra Walker
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1 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

2 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

3 Why Have a Robust Safety Program? We impact people with real lives and the world we live in Employees Associates Community Environment Images 2013 Portrait Innovations

4 Source: 2012 E. I. du Pont de Nemours and Company Bradley Curve Infographic Safety and Business Obvious Costs Direct costs Medical costs Wages Claims administration Indirect Costs (>5x direct costs) Damaged items Lost production/quality Replacement labor/efficiency General liabilities Litigation

5 Source: 2012 E. I. du Pont de Nemours and Company Bradley Curve Infographic Direct Cost Safety and Excellence 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

6 Safety and Business Money Saved Source: 2012 E. I. du Pont de Nemours and Company Bradley Curve Infographic

7 Injury Rate Source: 2012 E. I. du Pont de Nemours and Company Bradley Curve Infographic Safety From Instinct to Culture When building a program you can t skip steps

8 Researcher Responsibilities Administration 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.

9 How to Control Hazards Identify the hazards Control the hazards Assess the hazards Write the procedure Systematically review Risk Management System Act Check Plan Continuous Improvement Do Management Responsibility Which Requires Employee Participation

10 Potential Hazards on the Job: Chemical Toxins Carcinogens Flammables Oxidizers Reducers Pyrophorics Corrosives Etc

11 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

12 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

13 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

14 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) Identify Hazards 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

15 Engineering Automatic and intrinsic control Requires no human interaction Such as an electrical interlock Preferred Hazard Controls Elimination Do not utilize the hazard for the task Substitution Use a lower risk approach for the task

16 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

17 Two primary factors Evaluating Hazards 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

18 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

19 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

20 Relative Hazard Index Potential Severity of Hazard Catastrophic Severe Moderate Minor Likelihood of Occurrence or Exposure Frequent Probable Occasional Remote Improbable Serious RHI=3 Serious RHI=3 Low RHI=1 Serious RHI=3 Serious RHI=3 Low RHI=1 Low RHI=1 Low RHI=1 Minimal RHI=0 ANSI Z10 Definitions, we use moderate for ANSI s marginal and Minor for ANSI s Negligible

21 Example 1: Gas Cylinders Potential Severity of Hazard Catastrophic Severe Moderate Minor Death? Permanent Disability? Building Loss? Likelihood of Occurrence or Exposure Frequent Probable Occasional Remote Improbable Serious RHI=3 Serious RHI=3 Low RHI=1 Serious RHI=3 Serious RHI=3 Low RHI=1 Low RHI=1 Low RHI=1 Minimal RHI=0 Severity = Catastrophic Without Admin Controls Probability = Frequent With Admin Controls Probability = Occasional (clamp type brackets) Reduce probability by policy prohibiting bench clamps?

22 Example 2: 120V Electrical Cord Potential Severity of Hazard Catastrophic Severe Moderate Minor Death? Permanent Disability? Building Loss? Likelihood of Occurrence or Exposure Frequent Probable Occasional Remote Improbable Serious RHI=3 Serious RHI=3 Low RHI=1 Serious RHI=3 Serious RHI=3 Low RHI=1 Low RHI=1 Low RHI=1 Minimal RHI=0 Severity = Catastrophic With admin controls Probability = remote (fire and electrocution) Does the hazard index match your perception of risk? (serious) Does familiarity change hazard perception?

23 Example 3: 1100º C Muffle Furnace Potential Severity of Hazard Catastrophic Severe Moderate Minor Medical Treatment? Lost Work? Minor Facility Damage? Likelihood of Occurrence or Exposure Frequent Probable Occasional Remote Improbable Serious RHI=3 Serious RHI=3 Low RHI=1 Serious RHI=3 Serious RHI=3 Low RHI=1 Low RHI=1 Low RHI=1 Minimal RHI=0 Severity = Moderate With admin controls Probability = remote (for burn) Does the hazard index match your perception of risk? () Does familiarity change hazard perception?

24 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

25 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

26 Signal Words! DANGER! WARNING 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! CAUTION Notice 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

27 Globally Harmonized System (GHS) Pictograms Flammable Toxic Compressed gas Oxidizing Health Environmental Explosive Corrosive Irritant

28 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: P : IF ON SKIN: Wash with soap and water Storage: P403: Store in a well ventilated place Disposal: P501: Dispose of contents/container to

29 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

30 Standard/Safe Operating Procedures Items 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:

31 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

32 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 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)

33 Event Reporting Report injuries (24 hour time limit) HR Website Report hazards SPPM Form Report near misses Report near misses Report near misses Event reporting allows for detailed tracking and accident prevention

34 Probability Fraction 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 Number of Hazard Notifications

35 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

36 WSU Resources EHS Laboratory Safety Manual Chemical Waste Pickup Chemical Hygiene Plan and other templates for laboratories Safety Policies and Procedures Manual (SPPM) - 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)

37 Hazard Assessment: Review If anything can go wrong, it will go wrong 2 nd law of thermodynamics (AKA Murphy s Law).

-JHA- Job. For Science and Engineering. Hazard Assessment

-JHA- Job. For Science and Engineering. Hazard Assessment -JHA- For Science and Engineering Job Hazard Assessment Is a Job Hazard Assessment Necessary? The Occupational Safety and Health Administration regulations confirm a JHA is needed. OSHA 1910.132(d)(2)