CHME 690 August 2017 ESP Review & Jett Hall

1. CHME 690August 2017ESPReview & Jett Hall Engineering Is Discovery!

2. Why Safety • We all want to go home safe • All our fingers and toes • Feeling well and happy • Enjoy our research, jobs • Look forward to our future career • Maintain a sense of vulnerability – Something bad could happen so always be aware Engineering Is Discovery!

3. Case Study Poor Safety Practices February 2015, Texas Tech University Failure to Segregate Waste Streams Mixes Nitric Acid and Organic Solvent, Causes Waste Bottle to Explode From Pressure Buildup; Written Procedures Did Not Reflect Current Procedures Engineering Is Discovery!

4. Case Study Poor Safety Practices cont. • A glass waste bottle exploded • 3 undergraduate students and a graduate teaching assistant (TA) were injured and required medical attention • All students and personnel were wearing appropriate personal protective equipment including lab coats, safety goggles and gloves Engineering Is Discovery!

5. Case Study Poor Safety Practices cont. What caused this incident? • January 2015 - written instructions for the lab procedures included a step using a Nitric Acid wash • This step was removed from the procedure in 2011 but the written instructions were never changed (revised) • waste bottle contained Methanol and Dimethylglyoxime and nitric acid • The waste bottle was capped at the end of the experiment • Over the weekend the reaction in the bottle built up pressure until the student handled the bottle and it exploded Engineering Is Discovery!

6. Case Study Poor Safety Practices cont. • What could be done to prevent this? • Training on incompatible chemicals • Training on proper operating procedures • Update/revise procedures promptly when changes occur • Collect and destroy any old copies of written procedures Engineering Is Discovery!

7. Again Why Safety According to 7 reasons why workplace safety is so important by MFASCO (Health and Safety) • Injury • Death • Financial Loss • Property Damage • Worker productivity increases • Service or Quality of the product improves • Corporate reputation / public relations improves Engineering Is Discovery!

8. Industrial Hygiene • Industrial Hygiene is defined as: the science of protecting and enhancing the health and safety of people at work and in their communities. Health and safety hazards cover a wide range of chemical, physical, biological and ergonomic stressors. • Anticipation, recognition, evaluation and control of hazards have always been the prime goal for the industrial hygiene professional 2 2American Board of Industrial Hygiene, http://www.abih.org/content/ih-defined Engineering Is Discovery!

9. Case Study – Industrial Hygiene Awareness March 2018 – Texas Tech University Failure to Follow Spill Procedures Leads to Acute Chemical Exposure and Hospitalization Chemical involved was methylene chloride aka dichloromethane Engineering Is Discovery!

10. Case Study – Industrial Hygiene Awareness What Happened? • A four-liter glass bottle secondary container of dichloromethane (DCM) broke during a chemical transfer • No emergency services were called, nor was Environmental Health and Safety (EH&S) or the Departmental Safety Officer (DSO) notified immediately after the incident. • Approximately two hours after the incident, the student started to demonstrate symptoms of DCM exposure (dizziness, drowsiness, headache and nausea ) and was hospitalized for treatment. Engineering Is Discovery!

11. Case Study – Industrial Hygiene Awareness Details of incident: • After the worker dropped the bottle and it broke, they did not immediately exit the laboratory or use the safety shower located in the laboratory. • The worker stood in the corner next to the spill for approximately 15 minutes until the spill area had evaporated enough for them to get around it without stepping directly in the DCM. • During this time the worker received an acute inhalation exposure to DCM fumes. Engineering Is Discovery!

12. Case Study – Industrial Hygiene Awareness • The worker then went to the public bathroom and rinsed off their feet in the sink and changed into a different pair of shoes. • The worker then opened the laboratory doors to increase ventilation and allow the DCM to evaporate completely. • Once the DCM evaporated the worker went to class leaving the broken glass for other laboratory workers to clean up. • While in class the worker started to feel ill and contacted their primary care physician who told them to call 911 after they were informed of the exposure. Engineering Is Discovery!

13. Case Study – Industrial Hygiene Awareness What kinds of things went wrong here? • Person did not evacuate • Person did not call for assistance • Person self cleaned the spill • Person was in area with fumes way to long Do you think this person exposed others to this hazard? • Changed from contaminated shoes closed in restroom • Left lab door open to ventilate room • Left broken glassware to pick up later • Do you suppose the person had it on their clothes as well and people in the next glass got to smell it as well? Engineering Is Discovery!

14. Industrial Hygiene Evaluation Purposes of the industrial hygiene evaluation are: • Awareness of Chemical Hazards • Operation • Emergencies • Waste • Ensure appropriate PPE being used • Gloves • Smock • Fume Hood • Dry box Engineering Is Discovery!

15. Industrial Hygiene Evaluation Engineering Is Discovery!

16. Think Risk Management http://www.plasticisers.org/en_GB/health/risk-vs-hazard Engineering Is Discovery!

17. Experimental Safety Plans (ESPs) Engineering Is Discovery!

18. ESPApproach Extensively Rigorous – by design • Training • Ownership • Documentation • Experiment details • Administration • Change Management Engineering Is Discovery!

19. ESP Approach – Training • All researchers must complete a minimum of 5 safety courses prior to gaining access to a laboratory • CHME Laboratory Safety • Employee Safety • Laboratory Standard • Hazardous Communications • Hazardous Waste Management • Other safety training assigned based on specific chemical hazards or equipment Engineering Is Discovery!

20. ESP Approach – Review Process • ESP approval occurs in two phases. • Phase I is the preparation of a written safety plan. Upon approval of the written plan, researcher(s) may order equipment and necessary supplies, and begin to assemble experiment. Phase I also includes an evaluation by CHO (and if appropriate by EH&S) to establish controls of hazardous operations, avoid the purchase of inappropriate supplies, and establish expected waste(s) streams. • Everyone on ESP must complete Lab Commissioning to approve • Phase II approval requires evaluation of the assembled experiment, and a “dry run” of the experimental procedure or Emergency Shutdown Procedure. High Hazard work may be subject to approval by official university boards, including any work with radioactive materials or radiation producing machines, certain biological materials, animals and/or human subjects. Engineering Is Discovery!

21. ESP Approach - Ownership • Researcher responsible for completing the form • If they can explain the experiment they understand it • Ownership of requirements and processes • PI responsible for review of form • Are the experiments described what they wanted • Efficiency of data collection • CHO responsibilities for safety review • Processes and chemicals • Consultation and evaluation of risks • Department Head ultimate review authority Engineering Is Discovery!

22. ESP Document The Experimental Safety Plan is divided into the following seven sections: • Experiment Scope • Drawing of the laboratory or pilot area • Normal Operations, Startup and Shutdown Procedures • Emergency Shutdown Procedure and medical emergency instructions. • Waste Management Procedure • Hazard Identification and Mitigation • Safety Data Sheets Engineering Is Discovery!

23. ESP Approach – Scope • Researcher required to provide • Specific details of experiment - • Scope – Why the work is being performed • Stoichiometry • Thermal Safety • List all chemicals and equipment • Revisions – Highlight all changes Engineering Is Discovery!

24. ESP Approach – Drawing of Laboratory • Drawing of the laboratory including: • Location of workspace • Location of critical equipment • Safety equipment • Allows for review of conflicts with other research activities • P&ID Drawing of Process/Material Flow Engineering Is Discovery!

25. Example – Analytical Instrument Bomb Calorimeter

26. Photos of Bomb Calorimeter

27. ESP Approach – Detailed Procedures Engineering Is Discovery! • Detailed procedures • Normal Operation • Stepwise process of running the experiment • Including chemical additions and equipment used • Startup & Shutdown - Details • How to startup the process or experiment • How to shut it down • Maintenance procedures • Highlights when hazardous conditions exist and a risk analysis needs to be performed

28. ESP Approach – Emergency Procedures Engineering Is Discovery! • Emergency Shutdown Procedures • Consider what kinds of emergencies might happen • Researchers must consider how to deal with each scenario • Highlights if high hazard activities need a further consultation and risk analysis • We will talk about Risk Analysis and Methods in another seminar

29. Example – Emergency Procedures for Bomb Calorimeter Misfire: 1. In the case where the calorimeter misfires, stop the reaction. 2. Re- check for leaks (if there are continuous bubbles in the bomb calorimeter jacket) it may be due to the bomb cap not been sealed properly or the O-ring has worn out. 3. Vent the bomb slowly using the pin wrench, unscrew the bomb cap with care and ensure that the O-ring and the fuse wire are in good condition. 4. Check to see if the sample is well placed in the sample cup and that the sample cup holder is placed correctly. 5. Ensure that the fuse wire is touching the fuel sample before doing a re-run. 6. Follow the detailed procedure listed above for either standardization or determination runs. Engineering Is Discovery!

30. ESP Approach – Waste Management • Waste Management Procedures • Waste materials generated • Quantities of waste • Segregation plan for waste materials • Location of waste disposal • Review of waste plan by Environmental Health & Safety Department Engineering Is Discovery!

31. ESP Approach – Hazard Identification • Hazard Identification and Mitigation • Researcher reviews the experiments • Checklist of possible hazards • Hazards identified must describe • Operation and engineering controls used • Required PPE beyond minimum • Special Training beyond minimum • Consultation and review by CHO • Provides learning experience for researcher • Allows professional oversight of hazard controls and training Engineering Is Discovery!

32. ESP Approach – Safety Data Sheets • Complies with Hazard Communications • Provides information for Industrial Hygiene Review • Ensures they are all on file somewhere in our system Engineering Is Discovery!

33. Researcher Lab Commissioning Engineering Is Discovery!

34. Researcher Lab Commissioning • Everyone is required to go through the Lab Commissioning Training in order to work in the lab • One time training • List posted on CHME Research page with names • Ensures everyone hears the same story about the rules • Extra training may occur with ESP approval • Covers • Fume Hood Operation • Chemical Storage and Inventory • Labeling of Drawers, Shelves, Refrigerator etc. • Waste Collection: Locations, Containers and Labeling Supplies • Lab Safety Equipment and Emergency Exits Engineering Is Discovery!

35. Researcher Lab Commissioning Goal of lab commissioning • Every drawer, shelf, etc. has a label • Everyone is accountable for samples, chemicals and equipment • Everyone is accountable to keep their assigned area clean and in an appropriate state • Decommissioning upon graduation or departure to ensure that samples, chemicals and equipment are cleaned, dispose of or transferred to someone Engineering Is Discovery!