Chemiscal laborary safety and security a guide to prudent chemical management

Chemical Laboratory Safety and Security A Guide to Prudent Chemical Management Lisa Moran and Tina Masciangioli, Editors Committee on Promoting Safe and Secure Chemical Management in Developing Countries Board on Chemical Sciences and Technology Division on Earth and Life Studies THE NATIONAL ACADEMIES PRESS Washington, DC www.nap.edu Authoring Committee Credits Committee on Promoting Safe and Secure Chemical Management in Developing Countries From Pakistan: M IQBAL CHOUDHARY, University of Karachi From the Philippines: PATRICK J Y LIM, University of San Carlos, Cebu City From the United States: NED D HEINDEL (Chair) Lehigh University, Bethlehem, PA; CHARLES BARTON, Independent Consultant, San Ramone, CA; JANET S BAUM, Independent Consultant, University City, MO; APURBA BHATTACHARYA, Texas A&M University, Kingsville; CHARLES P CASEY, University of Wisconsin, Madison*; MARK C CESA, INEOS USA, LLC, Naperville, IL; ROBERT H HILL, Battelle Memorial Institute, Atlanta, GA; ROBIN M IZZO, Princeton University, NJ: RUSSELL W PHIFER, WC Environmental, LLC, West Chester, PA; MILDRED Z SOLOMON, Harvard Medical School, Boston, MA; JAMES M SOLYST, ENVIRON, Arlington, VA; USHA WRIGHT, O’Brien & Gere, Syracuse, NY *Member, U.S National Academy of Sciences NCR Staff: Tina Masciangioli, Study Director; Sheena Siddiqui, Research Assistant; Kathryn Hughes, Program Officer; and Lisa Moran, Consulting Science Writer This study was funded under grant number S-LMAQM-08-CA-140 from the U.S Department of State The opinions, findings and conclusions stated herein are those of the authors and not necessarily reflect those of the U.S Department of State We also gratefully acknowledge the following individuals and organizations who reviewed these materials: Temechegn Engida, Addis Ababa, Ethiopia; Mohammed El-Khateeb, Jordan University of Science and Technology; Alastair Hay, University of Leeds, United Kingdom; Pauline Ho, Sandia National Laboratories, Albuquerque, New Mexico, United States; Supawan Tantayanon, Chulalongkorn University, Bangkok, Thailand; Khalid Riffi Temsamani, University Abdelmalek Essâadi, Tétouan-Morocco; and Erik W Thulstrup, Valrose, Denmark Book layout and design by Sharon Martin; cover design by Van Ngyuen The Academy of Sciences for the Developing World Additional copies of this book are available for free on the Internet at www.nap.edu Copyright 2010 by the National Academy of Sciences All rights reserved Printed in the United States of America The National Academy of Sciences is a private, nonprofit, self-perpetuating society of distinguished scholars engaged in scientific and engineering research, dedicated to the furtherance of science and technology and to their use for the general welfare Upon the authority of the charter granted to it by the Congress in 1863, the Academy has a mandate that requires it to advise the federal government on scientific and technical matters Dr. Ralph J Cicerone is president of the National Academy of Sciences The National Academy of Engineering was established in 1964, under the charter of the National Academy of Sciences, as a parallel organization of outstanding engineers It is autonomous in its administration and in the selection of its members, sharing with the National Academy of Sciences the responsibility for advising the federal government The National Academy of Engineering also sponsors engineering programs aimed at meeting national needs, encourages education and research, and recognizes the superior achievements of engineers Dr. Wm A Wulf is president of the National Academy of Engineering The Institute of Medicine was established in 1970 by the National Academy of Sciences to secure the services of eminent members of appropriate professions in the examination of policy matters pertaining to the health of the public The Institute acts under the responsibility given to the National Academy of Sciences by its congressional charter to be an adviser to the federal government and, upon its own initiative, to identify issues of medical care, research, and education Dr Harvey V Fineberg is president of the Institute of Medicine The National Research Council was organized by the National Academy of Sciences in 1916 to associate the broad community of science and technology with the Academy’s purposes of furthering knowledge and advising the federal government Functioning in accordance with general policies determined by the Academy, the Council has become the principal operating agency of both the National Academy of Sciences and the National Academy of Engineering in providing services to the government, the public, and the scientific and engineering communities The Council is administered jointly by both Academies and the Institute of Medicine Dr Ralph J Cicerone and Dr Wm A Wulf are chair and vice chair, respectively, of the National Research Council Foreword As developing countries become more economically competitive and strive to increase capacity in chemical sciences, they face many challenges in improving laboratory safety and security Safety and security practices are intended to help laboratories carry out their primary functions in efficient, safe, and secure ways Improving safety and security is mistakenly seen as inhibitory, but lack of understanding of safety and security procedures, cultural barriers, lack of skills, and financial constraints can easily be overcome Promotion of good safety and security procedures can eventually lead to greater productivity, efficiency, savings, and most importantly, greater sophistication and cooperation It is for this reason that the U.S National Research Council set out to provide guidance for laboratories in the developing world on safe and secure practices in the handling and storage of hazardous chemicals A select committee composed of experts in synthetic organic and pharmaceutical chemistry and processing; chemical safety, security, and management; and chemical education and behavioral change examined the barriers to and needs for improving laboratory safety practices in developing countries An emphasis throughout the study was on understanding socioeconomic and cultural conditions of developing nations The committee’s findings are reflected in this book, which is based on the study Promoting Chemical Laboratory Safety and Security in Developing Countries, as well as the seminal reference book on chemical laboratory safety in the United States, Prudent Practices in the Laboratory: Handling and Management of Chemical Hazards Every day, chemists throughout the world work in laboratories with hazardous chemicals They also generally follow the necessary procedures for safe handling and disposal of these chemicals It is our hope that this book and the accompanying materials will assist chemists in developing countries to increase the level of safety and security in their labs through improved chemicals management and following the best laboratory practices possible This book and accompanying materials are based on two reports of the National Research Council: Prudent Practices in the Laboratory: Handling and Management of Chemical Hazards, which serves as a seminal reference book on chemical laboratory safety in the United States and was prepared by the Committee on Prudent Practices in the Laboratory: An Update; and v Foreword Promoting Chemical Laboratory Safety and Security in Developing Countries, prepared by the Committee on Promoting Safe and Secure Chemical Management in Developing Countries Both books are available on the Internet through the National Academies Press at www.nap.edu vi Contents Executive Summary Why Are Chemical Safety and Security Important for Your Institution? Fostering a Culture of Chemical Safety and Security Responsibility and Accountability for Laboratory Safety and Security Types of Hazards and Risks in the Chemical Laboratory Enforcing Laboratory Safety and Security Finding and Allocating Resources What Can You Do to Improve Chemical Safety and Security? Ten Steps to Establish a Safety and Security Management System Chemical Safety and Security at the Laboratory Level 2 9 11 The Culture of Laboratory Safety and Security 13 Establishing an Effective Chemical Safety and Security Management System 15 2.1 2.2 2.3 Introduction Whose Job Is It? Responsibility for Laboratory Safety and Security Ten Steps to Creating an Effective Laboratory Chemical Safety and Security Management System Emergency Planning 3.1 3.2 3.3 3.4 3.5 3.6 19 25 Introduction Developing an Emergency Preparedness Plan Assessing Laboratory Vulnerabilities Identifying Leadership and Priorities Creating a Plan Emergency Training Implementing Safety and Security Rules, Programs, and Policies 4.1 4.2 4.3 4.4 4.5 4.6 4.7 16 16 Introduction Essential Administrative Controls Inspections Incident Reporting and Investigation Enforcement and Incentive Policies Best Practices of a Performance Measurement Program Twelve Approaches to Following Best Practices vii 26 26 27 27 28 35 37 38 38 39 40 40 41 42 Contents Laboratory Facilities 5.1 5.2 5.3 5.4 5.5 5.6 47 Introduction General Laboratory Design Considerations Laboratory Inspection Programs Laboratory Ventilation Special Systems Ventilation System Management Program Laboratory Security 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10 59 Introduction Security Basics Establishing Levels of Security Reducing the Dual-Use Hazard of Laboratory Materials Establishing Information Security Conducting Security Vulnerability Assessments Creating a Security Plan Managing Security Regulatory Compliance Physical and Operational Security Assessing Hazards and Risks in the Laboratory 7.1 7.2 7.3 7.4 7.5 7.6 7.7 Introduction Consulting Sources of Information Evaluating the Toxic Risks of Laboratory Chemicals Assessing the Toxic Risks of Specific Laboratory Chemicals Assessing Flammable, Reactive, and Explosive Hazards Assessing Physical Hazards Assessing Biohazards Managing Chemicals 8.1 8.2 8.3 8.4 8.5 8.6 48 48 50 50 54 55 60 60 61 63 64 65 66 67 68 69 71 73 73 74 75 80 88 90 91 Introduction Green Chemistry for Every Laboratory Purchasing Chemicals Inventory and Tracking of Chemicals Storage of Chemicals Transfer, Transport, and Shipment of Chemicals Working with Chemicals 92 92 95 97 98 104 105 9.1 Introduction 9.2 Careful Planning 9.3 General Procedures for Working with Hazardous Chemicals 9.4 Working with Substances of High Toxicity 9.5 Working with Biohazardous Materials viii 107 107 108 120 122 Contents 9.6 9.7 Working with Flammable Chemicals Working with Highly Reactive or Explosive Chemicals 10 Working with Laboratory Equipment 10.1 10.2 10.3 10.4 10.5 Introduction Working with Electrically Powered Equipment Working with Compressed Gases Working with High and Low Pressures and Temperatures Using Personal Protective, Safety, and Emergency Equipment 11 Managing Chemical Waste 11.1 11.2 11.3 11.4 11.5 123 125 135 137 137 139 143 148 151 Introduction Identifying Waste and Its Hazards Collecting and Storing Waste Treatment and Hazard Reduction Disposal Options ix 152 153 154 158 160 Contents: Appendixes The following appendixes are available on the CD attached to the inside back cover of the book Appendixes A A.1 Example List of Chemicals of Concern 165 B B.1 Sources of Chemical Information 175 C C.1 Types of Inspection Programs 181 184 186 D D.1 Design Considerations for Casework, Furnishings, and Fixtures 188 190 192 195 E E.1 Developing a Comprehensive Security Vulnerability Assessment 197 F 201 C.2 Elements of an Inspection C.3 Items to Include in an Inspection D.2 Laboratory Engineering Controls for Personal Protection D.3 Laboratory Hoods D.4 Maintenance of Ventilation Systems F.1 Assessing Routes of Exposure for Toxic Chemicals F.2 Assessing Risks Associated with Acute Toxicants F.3 Flash Points, Boiling Points, Ignition Temperatures, and Flammable Limits of Some Common Laboratory Chemicals F.4 Chemicals That Can Form Peroxides F.5 Specific Chemical Hazards of Select Gases 204 206 207 209 G G.1 Setting Up an Inventory 211 214 H H.1 Personal Protective, Safety, and Emergency Equipment 215 G.2 Examples of Compatible Storage Groups H.2 Materials Requiring Special Attention Due to Reactivity, Explosivity, or Chemical Incompatibility I I.1 I.2 I.3 J J.1 J.2 Precautions for Working with Specific Equipment Guidelines for Working with Specific Compressed Gas Equipment Precautions When Using Other Vacuum Apparatus How to Assess Unknown Materials Procedures for Laboratory-Scale Treatment of Surplus and Waste Chemicals x 221 229 237 240 242 246 ... that are relevant to its operating units the operations of the laboratory, are practical to carry out, and comply with the law and basic standards of safety and security Chemical Safety and Security. .. integrating safety and security into small-scale chemical laboratories Creating a safety and security management system will improve laboratory operations and anticipate and prevent circumstances... Responsibility and Accountability for Laboratory Safety and Security Laboratory safety and security require mandatory rules and programs, a commitment to them, and consequences when those rules and expectations