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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0.25

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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).