Laboratory Safety Manual Final PDF

FFC Laboratory Goth Machhi Laboratory Safety Manual Prepared By: Fawad Ahmed EX -TS (LAB) Approved By: M Shoaib DM-TS (LAB) Rev. 1.0 Dec 2020 LABORATORY SAFETY MANUAL Introduction...

FFC Laboratory Goth Machhi Laboratory Safety Manual Prepared By: Fawad Ahmed EX -TS (LAB) Approved By: M Shoaib DM-TS (LAB) Rev. 1.0 Dec 2020 LABORATORY SAFETY MANUAL Introduction Fauji Fertilizer Company is one of a few companies of the country that gives paramount importance to Health Safety and Environment. It inculcates the safety culture in the minds of the employee which differentiates it from the rest of the society. It has international certification of OHSAS (Occupational Health & Safety Assessment Series) that further boosts its stature at corporate sector. Its Occupational Health & Safety policy states “We are committed to maintain a safe and healthy environment having the same significance as productivity We inculcate safety culture by specific training, incentives, and effective control, to ensure a safe and healthy working environment We resolve to attain the highest standards of safety and health through consistent improvements in on‐the‐job and off‐the‐job safety and in the working conditions.” Similarly FFC Laboratory is in line with the safety culture that prevails in the Company. This manual will provide the basic guidelines for safe practices in lab, chemical & glassware handling, Sampling, Emergency Measures, Hazard Measurement, Identification, Instrument Safety, Compressed Gas Cylinder Handling, Chemical Awareness and Training. Rev. 1.0 Dec 2020 Page 1 of 52 LABORATORY SAFETY MANUAL Table of Contents 1.0 Glassware Handling 1.1 Glass 1.2 Glass Classification 1.3 Properties of glass 1.4 Forms of glassware 1.5 Choice of glassware 1.6 Inspection of glassware 1.7 Washing / Cleaning 1.8 Heating / Cooling 1.9 Disposal 2.0 Chemical Handling 2.1 Introduction 2.2 Chemical Understanding 2.3 Poisons 2.4 Highly Toxic solids 2.5 Toxic / Flammable Gases 2.6 Toxic Liquid and Severe irritants 2.7 Carcinogens 2.8 Oxidizers 2.9 Corrosives (Acids & Alkalis) 2.10 Reactive 2.11 Compressed Gas Cylinders 2.12 Routs for Absorption of Chemicals and Prevention. 3.0 Working on Instruments 3.1 Gas Chromatograph 3.2 Polarograph 3.3 Kjeldhal Apparatus 3.4 UV‐Visible spectrometer 3.5 Atomic Absorption Spectrometer Rev. 1.0 Dec 2020 Page 2 of 52 LABORATORY SAFETY MANUAL 4.0 Basic Emergency Measures and First Aid 4.1 Basic Awareness of Fire & Fire Fighting 4.2 Chemical Spills 4.3 Acid Caustic Spills on body 4.4 Bleeding and Hemorrhage 4.4.1 Pressure Point 4.4.2 The Tourniquet 4.5 First Aid Facilities 4.6 First Aid 4.6.1 Unconsciousness 4.6.2 Electric Shock 4.6.3 Burns 4.6.4 Gas Inhalation 4.6.5 Ingestion of Chemicals 4.6.6 Skin Contact 4.6.7 Eye Contamination 5.0 Safe Laboratory Practices 5.1 Avoid of Routine Exposure 5.2 Choice of Chemicals 5.3 Eating, Drinking, Smoking, etc. 5.4 Equipment and glassware 5.5 Decontamination 5.6 Horseplay 5.7 Mouth suction 5.8 Personal Apparel 5.9 Personal Housekeeping 5.10 Personal Protective Equipments (PPEs) 5.11 Unattended Operations 5.12 Use of fume hoods 5.13 Vigilance 5.14 Waste Disposal 5.15 Notification 5.16 Visitors 5.17 Signs, Labels, Hazard Identification Rev. 1.0 Dec 2020 Page 3 of 52 LABORATORY SAFETY MANUAL Unit# 1 Glassware and Glassware Handling 1.1 Glass: Glass is an amorphous (non‐crystalline) solid material. Chemically it is Silicates, Borates, Aluminates of Alkali and Alkaline Earth Metals. It is made by fusing together a mixture of clean sand, limestone, or red lead in appropriate proportions. It can be molded to any shape. It may be colored, transparent, or opaque. 1.2 Classification of Glass: Glass is classified according to chemicals used and the process of manufacturing. 1.2.1 Soft /Soda Glass: It is the most common variety of glass. It is prepared by heating sodium carbonate and silica. It is used for making windowpanes, tableware, bottles and bulbs. 1.2.2 Plate glass: Plate glass is thicker than ordinary glass. It has very smooth surface. It is made by floating a layer of molten glass over a layer of molten tin. It is used in shop windows and doors. 1.2.3 Alumino‐silicate Glass: A small, but important type of glass, alumino‐silicate, contains 20% aluminum oxide (alumina‐ Al2O3) often including calcium oxide, magnesium oxide and boric oxide in relatively small amounts of soda or potash. It is able to withstand high temperatures and thermal shock and is typically used in combustion tubes, gauge glasses for high‐pressure steam boilers, and in halogen‐ tungsten lamps capable of operating at temperature as high as 750°C. 1.2.4 Borosilicate Glass / Pyrex: Borosilicate glass, the third major group, is made mainly of silica (70‐80%) and boric oxide (7‐ 13%) with smaller amounts of the alkalis (sodium and potassium oxides) and aluminum oxide. This type of glass has relatively low alkali content and consequently has good chemical durability and thermal shock resistance. As a result it is widely used in the chemical industry, for laboratory apparatus, for ampoules and other pharmaceutical containers, for various high intensity lighting applications and as glass fibers for textile and plastic reinforcement. Rev. 1.0 Dec 2020 Page 4 of 52 LABORATORY SAFETY MANUAL 1.2.5 Glass Ceramics: Glass ceramics are formed typically from lithium alumino‐silicate glass, are extremely resistant to thermal shock and have found several applications where this property is important, including cooker hobs, cooking ware, windows for gas or coal fires boilers, mirror substrates for astronomical telescopes and missile nose cones. An essential feature of glass is that it does not contain crystals. However, by deliberately stimulating crystal growth in glass it is possible to produce a type of glass with a controlled amount of crystallization that can combine many of the best features of ceramics and glass 1.2.6 Glass Fiber: Glass fiber has many uses from roof insulation to medical equipment and its composition varies depending on its application. For building insulation and glass wool the type of glass used is normally soda lime. For textiles, an alumino‐borosilicate glass with very low sodium oxide content is preferred because of its good chemical durability and high softening point. This is also the type of glass fiber used in the reinforced plastics to make protective helmets, boats, piping, car chassis, ropes, car exhausts and many other items. In recent years, great progress has been made in making optical fibers which can guide light and thus transmit images round corners. These fibers are used in endoscopes for examination of internal human organs, changeable traffic message signs now on motorways for speed restriction warnings and communications technology without which telephones and the internet would not be possible. 1.2.7 Lead Glass: Commonly known as lead crystal, lead glass is used to make a wide variety of decorative glass objects. It is made by using lead oxide instead of calcium oxide, and potassium oxide instead of other alkali metal oxides. Glass containing less than 24% PbO, is known simply as crystal glass. The lead is locked into the chemical structure of the glass so there is no risk to human health. Lead glass has a high refractive index making it sparkle brightly and a relatively soft surface so that it is easy to decorate by grinding, cutting and engraving which highlights the crystal's brilliance making it popular for glasses, decanters and other decorative objects. Glass with even higher lead oxide contents (typically 65%) may be used as radiation shielding because of the well‐ known ability of lead to absorb gamma rays and other forms of harmful radiation. 1.2.8 Jena Glass: It is a mixture of Zinc and Barium‐Boro‐Silicates, very resistive to heat, shock and common reagents. Rev. 1.0 Dec 2020 Page 5 of 52 LABORATORY SAFETY MANUAL 1.2.9 Crooks Glass: It is a special type of optical glass containing cerium oxide which cuts off the ultra violet rays. 1.2.10 Colored Glass: It is a special type of glass in which small amounts of metallic oxides is mixed with the hot molten mixture of sand, sodium carbonate and limestone. The desired color determines the choice of the metallic oxide to be added, as different metallic oxides give different colors to the glass. 1.2.11 Safety / Laminated Glass: Laminated glass is a type of safety glass that holds together when shattered. In the event of breaking, it is held in place by an interlayer, typically of polyvinyl butyral (PVB), between its two or more layers of glass. The interlayer keeps the layers of glass bonded even when broken, and its high strength prevents the glass from breaking up into large sharp pieces. This produces a characteristic "spider web" cracking pattern when the impact is not enough to completely pierce the glass. It is used in automobile wind screen and in safety goggles. 1.3 Properties of Glass:  It is amorphous, hard and brittle, usually transparent and can be colored or opaque.  It breaks with a conchoidal fracture i.e. fracture characteristics of an amorphous solid  It is non conductor to electrical current.  It is capable of taking a high polish and while in a fused condition it can be made to assume almost any desired shape which it retains permanently when cold  It is non reactive towards solvents and water other than dissolved fluorides.  It is Capable of cutting in to desire shape. 1.4 Laboratory Glassware: Glassware is an integral part in any Quality Control Lab. Some important types of glassware are listed as. Tubes: Test Tube, U‐Tube, Delivery Tubes, Filling Tubes. Flasks: Measuring Flasks, Nitrogen Flasks, Erlenmeyer Flasks, Conical Flask, Round Bottom Flask, Quick Fit Flask, Vacuum Flask, Distillation Flask, Distribution Flask, Ejector Flask etc. Miscellaneous: Various types of Cylinders, Pipettes, Burettes, Policeman, Beakers, Reagent Bottles, Aspirator Bottles, Evaporation Dish etc. Rev. 1.0 Dec 2020 Page 6 of 52 LABORATORY SAFETY MANUAL 1.5 Choice of Glassware: Before doing analysis it is very important to select proper glassware. Use of Inappropriate glassware may lead to erratic results and in some cases can produce unsafe condition or an incident. If glass apparatus is not suitable for any particular analysis then use alternative apparatus (Plastic). 1.6 Inspection of Glassware: Using cracked, damaged or defective glassware is a big hazard. It is mandatory to inspect closely any damage to glassware prior to analysis. Damage glassware should be immediately replaced and recorded. Regular inspection of glassware may be conducted (daily, weekly) to avoid any hazard or incident. 1.7 Washing / Drying: All glassware should be thoroughly cleaned, dry before being employed in preparative work in the Laboratory. It is well to be developing the habit of cleaning all glass apparatus immediately after use. Detergent Washing: For routine washing detergent is used. It can be introduced directly into the apparatus and moistened with little water or else it must be applied to the dirty surface with a wet test tube brush which has been dipped into the powder solution, the glass surface is scrubbed until the dirt has been removed. The operation is repeated if necessary. Finally, the apparatus is thoroughly rinsed with distill water. If scrubbing with the water washing powder mixture is not entirely satisfactory, use of very dilute acid or alkali may be employed. Acid Washing: If the residue in flask is basic, dilute HCl, may be employed for complete dissolution. In case of metal contaminants rinse the apparatus with commercial HCl or heat if required. Base Washing: If residue is acidic, add commercial alkali and gently warm if required. Oily or greasy apparatus may be cleaned by using organic solvent (kerosene, Spirit etc.). Chromic Acid Treatment: The most widely used cleaning agent is the "Chromic Acid". It is essentially a mixture of chromium‐trioxide and concentrated sulfuric acid. It possesses a powerful oxidizing and solvent properties. It is prepared by two methods: a) Dissolve 5 g of Sodium / Potassium dichromate in 5 ml of water in a 250 ml beaker add 100 ml of concentrated sulfuric acid slowly with "constant stirring. The temperature will rise to 70 ‐ 80°C. Cool to 40°C and then transferred Pre‐dried glass stopper bottle. Rev. 1.0 Dec 2020 Page 7 of 52 LABORATORY SAFETY MANUAL Method: Before using the chromic acid mixture, rinses the apparatus with water to remove organic matter and particularly reducing agents as far possible. Add appropriate amount of the cleaning mixture into the vessel swirl it to cover all solid surface so that all insoluble material dissolve. Return the cleaning mixture back to the stock bottle. Some Important Points:  Use all personal protective before cleaning glass apparatus with chemicals  Acid treatment of glass apparatus should be done in fume hood.  Wear rubber gloves while cleaning the glass apparatus with acid or alkalis.  Handle one glassware at one time.  Avoid spills and take extra care.  If heating is required heat the apparatus on wire gauze.  Glassware Drying: Small glass apparatus may be dried by heating it in electrically heated oven maintained at 100 ‐ 105°C for about 1 hour. However, if apparatus is bigger for oven drying then use air, which should preferably warm. Or rinse the apparatus with little industrial spirit or acetone. After rinsing with the organic solvent, the subsequent drying is more conveniently done with the aid of the warm air blower. Many apparently simple manipulations such as the cutting of glass tubing or rod, the insertion of glass tubing or thermometers into bungs or corks, or the removal of tight stoppers from bottles, can lead to serious cuts. Following procedure is should be adopted for inserting the glass rod / tube into the stopper.  Make sure that the diameter of the tube is compatible with the diameter of the hole in the stopper.  Fire‐polish the end of the glass tube.  Lubricate the glass with water or glycerol.  Wear heavy duty cotton gloves and hold the glass tube not more than one inch from the end to be inserted.  Insert the glass carefully with a twisting motion.  Remove stuck tubes by slitting the stopper with a sharp knife. Assembling Glass Apparatus:  Firmly clamp apparatus and set up away from the edge of the lab bench.  Only use equipment that is free from cracks, chips, or other defects.  If possible, place a pan under a reaction vessel to avoid spills in case reaction vessel breaks. Rev. 1.0 Dec 2020 Page 8 of 52 LABORATORY SAFETY MANUAL  Do not allow burners or any other ignition sources nearby when working with flammable liquids.  Lubricate glass stopcocks.  Properly support and secure condensers and water hoses with clamps and wires.  Do not connect water connections close to the electrical circuit or receptacle.  Position the apparatus centrally while held with a ring stand and clamp it properly.  Assemble the apparatus so that burners or baths can be removed quickly.  Use an appropriate vapor trap and confine the setup to a fume hood if there is a possibility of hazardous vapors. 1.8 Heating / Cooling: Heating: Glass apparatus is heated as per requirement of the analysis. Following Safety measures should be taken while doing this. Do not heat glass apparatus directly on naked flame. Hot plate with wire gauze or water bath can be used.  Do not heat volumetric flask containing solution more then 1/3 of its total volume.  Remove stopper / lid from apparatus while heating.  Apparatus containing organic solvent is to be heated on water bath.  Use tong for removing glass apparatus from hot plates / mantles  For crackle test keep the mouth of the test tube away from the analyst while heating on naked flame. Cooling: Apparatus after heating is cool down. Following safety measures are taken.  Cooling of the apparatus should be done slowly. Sudden cooling may cause breakage.  Do not cool the heated apparatus in refrigerator.  Oven dried apparatus should be cooled in desiccators. 1.8 Disposal:  Keep broken / damaged glass apparatus in a labeled container.  Handling of broken apparatus must be carried out with extreme care. Wear cotton gloves and pick larger glass pieces. Smaller pieces are collected by the broom/brush latter dumped in trash bin. Unit # 2 Chemical Handling Rev. 1.0 Dec 2020 Page 9 of 52 LABORATORY SAFETY MANUAL 2.1 Introduction: Chemicals are a proportionate combination of atoms. They can be solid, liquid or gas. There are uncountable chemicals in the existing universe; some are natural and other manmade. These are broadly classified into two categories. Organic chemicals; that contain carbon hydrogen and oxygen. Other type is inorganic chemicals they contain atoms other than carbon and hydrogen. 2.2 Identification of Chemicals: A very small quantity of chemical is useful for human, but most of the chemicals are Poisonous, Toxic, Corrosive, Carcinogenic and Irritating. Lab Personnel working with such chemicals should be well aware from its health effects by understanding MSDS of these chemicals. A generic overview of some of chemicals is covered as under: 2.3 Poisons: General Characteristics: Poisons are chemicals that trigger risk to life. There are many types of poisons but the poisonous effects of chemical compounds can be classified as “Acute” (Short term) or 'Chronic' (long term). Chemicals that come under “Acute Poisons” produce immediate effect on life even for very short term exposure which can also lead to death. Cyanide, Thiocyanide posses such properties. On the other hand “Chronic Poisons”, show effect on life after long term exposure of small quantities. This type of insidious poisoning is harder to detect (and therefore prevent) since the effects may only manifest themselves after months or even years of exposure (or even long after exposure has ceased). Symptoms: Chronic poisoning may cause symptoms which are not easily recognizable as such, e.g. sleeplessness, irritability, memory lapses and minor personality changes. Handling: Such chemicals at first place should not be used or if their use is inevitable then a great care should be taken to avoid any type of contact with skin. Rubber gloves, dust mask are mandatory for handling poisons. Health Effect: Rev. 1.0 Dec 2020 Page 10 of 52 LABORATORY SAFETY MANUAL It must be stressed, however, that the final results of chronic poisoning may be very serious and can lead to premature death. Working with Poisons: Every effort should be made by the Laboratory Personnel to take guard against these possibilities by adopting a rigorous approach to the avoidance of breathing all vapors, dusts, and of any contact between the skin and liquids or powders. The guiding principle for all workers should be treat all chemicals potentially harmful unless one has positive knowledge so the contrary. Compounds with acute toxic properties which are likely to be encountered in laboratories are listed in laboratory with their toxic effects and preventive measures. Every lab personnel should familiarize with them. 2.4 Highly Toxic Solids: Even small quantity of these substances is likely to rapidly cause illness or even death. Particular care should be taken to avoid inhalation of dust and absorption through the skin or ingestion. These compounds are  Arsenic Compounds  Inorganic Cyanides  Mercury Compounds particularly inorganic salts & alkyl mercurials.  Cadmium compounds  Vanadium Penta‐Oxide. 2.5 Toxic/ Flammable Gases: All operations involving the use or liberation of these substances must be carried out in fume hood. Furthermore any skin contact or inhalation and spark producing source must be avoided. These gases are  Carbon Monoxide  Cyanogens  Chlorine  Hydrogen Fluoride  Hydrogen Sulfide  Nitrogen Oxide & Nitrosyl chloride  Ozone  Phosgene Rev. 1.0 Dec 2020 Page 11 of 52 LABORATORY SAFETY MANUAL  Phosphine  Ammonia  Methane  Hydrogen  Acetylene 2.6 Toxic Liquids and Severe irritants: These substances have dangerously toxic vapors and are also harmful through skin absorption. Prolonged exposure to small amounts is likely to give rise to chronic effects. These vapors are irritant to the respiratory system and eyes. These compounds are  Acetic Acid  Benzene  Bromine  Pyridine  Chloroform  Methane dichloride  Hydrochloric Acid  Nitric Acid  Hydrofluoric Acid  Carbon disulfide 2.7 Carcinogens: General Characteristics Many organic compounds have been shown to cause cancerous tumors in man, although the disease may not detect for several years. In addition to the compounds known to be carcinogenic to man, many substances have been shown to cause cancer in experimental animals and must therefore be presumed to be active in man. Handling: When handling known or suspected carcinogens, every effort should be made to avoid inhalation of their vapors and contamination of the skin. They must only be handled in fume hood using protective gloves, mask along with other mandatory PPEs. It is essential that bottles or viols containing the compounds should be properly labeled with suitable warnings. Supplies of carcinogenic compounds should be kept in a locked container, preferably in a fume hood. Rev. 1.0 Dec 2020 Page 12 of 52 LABORATORY SAFETY MANUAL Aromatic amines and their derivatives all be treated as potentially carcinogenic, and as a group probably constitute the greatest danger to the lab personnel since even slight exposure may initiate the formation of tumors. The following compounds and their salts are proven powerful carcinogens:  4‐Aminobiphenyl (Benzidine)  O‐Toludine  2‐Naphthylamine  1‐Naaphthylamine  4‐Aminostibene  O‐ Aminoazotoline  Thiosemicarbazide  Dianthramide  Eriochromeblack‐T  Muroxide  N,N‐Dimethy‐p‐Phenylene Diamine 2HCl  Piperazine  2,2‐Bipyridine  Chromo tropic Acid  Biphenyl Carbazide  ECOL  HMTA  Toluene  Thio‐urea  Thio‐acetamide (source of H2S),  Asbestos, lead and mercury compounds All Nitrosoamines (R'‐N (NO) R) and Nitrosamides (R'‐N (NO) CO‐R) should be regarded as potentially powerful carcinogens since most compounds of these types have been shown to possess high activity in experimental animals. 2.8 Oxidizers: General Characteristics: Oxidizers present fire and explosion hazards on contact with flammable and combustible materials. Depending on the class, an oxidizing material may increase the burning rate of Rev. 1.0 Dec 2020 Page 13 of 52 LABORATORY SAFETY MANUAL combustibles which it contacts; cause the spontaneous ignition of combustibles which it contacts, or produce an explosive reaction when exposed to heat, shock or friction. Examples of Common Oxidizers:  Peroxides Chlorates  Nitrates Chlorites  Nitrites Perchlorates  Hypochlorites Dichromates Handling:  Store oxidizers away from flammables, organic compounds and combustible materials.  Strong oxidizing agents like chromic acid should be stored in glass or some other inert container. Corks and rubber stoppers should not be used.  Reaction flasks containing oxidizing material should be heated in a mantle or sand bath. Oil baths should not be used. Use and storage of Perchloric Acid:  Perchloric acid is an oxidizing agent of particular concern. The oxidizing power of perchloric acid increases as the concentration and temperature increase. Cold, 70% perchloric acid is a strong, non‐oxidizing corrosive. A 72% perchloric acid solution at elevated temperatures is a strong oxidizing agent. An 85 % perchloric acid solution is a strong oxidizer at room temperature.  Do not attempt to heat perchloric acid if you do not have access to a properly functioning perchloric acid fume hood. Perchloric acid can only be heated in a hood specially equipped with a wash down system to remove any perchloric acid residue.  The hood should be washed down after each use, and it is preferred that the hood be restricted to perchloric acid use only.  Whenever possible, substitute a less hazardous chemical for perchloric acid or use a dilute solution.  Perchloric acid can be stored in a perchloric acid fume hood. Keep only the minimum amount necessary for your work. Another acceptable storage site for perchloric acid is in an acid cabinet that has secondary containment.  Do not allow perchloric acid to come in contact with any strong dehydrating agents such as sulfuric acid. The dehydration of perchloric acid is a severe fire and explosion hazard. Rev. 1.0 Dec 2020 Page 14 of 52 LABORATORY SAFETY MANUAL  Do not order or use anhydrous perchloric acid. It is unstable at room temperature and can decompose spontaneously with a severe explosion. Anhydrous perchloric acid will explode upon contact with wood.  Consult with Chemist before working with perchloric acid. Health Hazard Associated with Oxidizers: Acute Hazard: Some oxidizers such as nitric and sulfuric acid vapors, chlorine, and hydrogen peroxide act as irritant gases. All irritant gases can cause inflammation in the surface layer of tissues when in direct contact. They can also cause irritation of the upper airways, conjunctiva, and throat problems.  Fluorine can cause severe burns of the skin and mucus membranes.  Chlorine trifluoride is extremely toxic and can cause severe burns to tissue.  Nitrogen trioxide is very damaging to tissue, especially the respiratory tract. Then symptoms from an exposure to nitrogen trioxide may be delayed for hours, but fatal pulmonary edema may result. Chronic Effects: Nitrobenzene and chromium compounds can cause hematological and neurological changes. Compounds of chromium and manganese can cause liver and kidney disease. Chromium (VI) compounds have been associated with lung cancer. First Aid: If a person has inhaled, ingested or come into direct contact with these materials, the person should be removed from the immediate area as quickly as possible. Seek medical attention immediately. Rinse with a safety shower for at least 15 minutes if there is direct skin exposure. Flush with eyewash for at least 15 minutes if there is direct eye exposure. Personal Protective Equipments: Neoprene, polyvinyl chloride (PVC), or nitrile gloves are acceptable. Safety glasses must be worn if the potential for splashing or exposure to vapor/gas exists. Oxidizers should be used in a chemical fume hood due to the inhalation hazard risk. 2.9 Corrosives (Acid / Bases): General Characteristics:  Corrosives are most commonly acids and bases, but many other materials can be severely damaging to living tissue. Rev. 1.0 Dec 2020 Page 15 of 52 LABORATORY SAFETY MANUAL  Corrosives can damage tissue. Inhalation of the vapor or mist can cause severe bronchial irritation. Corrosives are particularly damaging to the skin and eyes.  Certain substances considered non‐corrosive in their natural dry state are corrosive when they come in contact with moist skin or mucus membranes. Examples include lithium chloride, halogen fluorides, and allyl iodide.  Sulfuric acid is a very strong dehydrating agent while nitric acid is a strong oxidizing agent. Dehydrating agents can cause severe burns to the eyes due to their affinity for water Examples: Sulfuric Acid Hydrochloric Acid Nitric Acid Chromic Acid Ammonium Hydroxide Bromine Chlorine Sodium Hydroxide Potassium Hydroxide Use and storage of Corrosives:  Always store acids and bases separately. Store acids in acid storage cabinets or plastic and keep them away from flammables. Acids stored in storage cabinets  Do not work with corrosives unless an emergency shower and eyewash are available within 10 sec travel time. (Currently this requirement is fulfilled by water taps available on sinks).  Add acid to water, but never add water to acid.  Do not store liquid acids above eye level. Store on a low shelf or inside a cabinet.  Store acids in a plastic tray, tub or rubber bucket to contain any leakage.  Purchase corrosives in containers that are plastic coated, this will reduce the danger to personnel if the container is dropped. Rev. 1.0 Dec 2020 Page 16 of 52 LABORATORY SAFETY MANUAL  Store acids in an acid cabinet or one that has a corrosion‐resistant lining. Acids stored in an ordinary metal cabinet will quickly corrode the interior. If an acid cabinet is not available, store the corrosive in a plastic tub inside a wooden cabinet.  Nitric acid should always be stored away from other acids and organic materials in a separate cabinet or compartment due to its high reactivity. Hydrofluoric Acid:  Hydrofluoric acid can cause severe burns. Inhalation of anhydrous hydrogen fluoride can be fatal. Initial skin contact with hydrofluoric acid may not produce any symptoms. However, hydrofluoric acid can scavenge calcium for the skin and bones, causing severe injuries.  Always use hydrofluoric acid in a properly functioning fume hood. Wear personal protective clothing.  If you suspect that you have come in direct contact with hydrofluoric acid; wash the area with water for at least 5 minutes, then apply cream. Remove contaminated clothing and seek medical attention. If hydrogen fluoride vapors are inhaled, move the person immediately to an uncontaminated atmosphere (if safe to do so) and seek prompt medical attention.  Never store hydrofluoric acid in a glass container as it is incompatible with glass.  Hydrofluoric acid usually comes in a plastic bottle.  Store hydrofluoric acid separately in an acid storage cabinet and keep only the amount necessary in the lab. Creams such as calcium gluconate for treatment of hydrofluoric acid exposure are commercially available and should be stored in the lab. Calcium gluconate reacts with hydrofluoric acid reducing attack of calcium in the body. Health Hazard:  All corrosives possess the property of being severely damaging to living tissues. Acids also react with other materials such as metals.  Skin contact with alkali metal hydroxides (e.g., sodium hydroxide and potassium hydroxide) is more dangerous than with strong acids. Contact with base metal hydroxides normally causes deeper tissue damage because there is less pain than with an acid exposure. The exposed person may not wash it off thoroughly enough.  All hydrogen halides are acids that are serious respiratory irritants and also cause severe burns. Acute: Rev. 1.0 Dec 2020 Page 17 of 52 LABORATORY SAFETY MANUAL Inhalation ‐ irritation of mucus membranes, difficulty in breathing, fits of coughing, pulmonary edema. Ingestion ‐ irritation and burning sensation of lips, mouth, and throat, pain in swallowing, swelling of the throat, painful abdominal cramps, vomiting and risk of perforation of the stomach. Skin Contact ‐ burning, redness and swelling, painful blisters, profound damage to tissues and with alkalis, a slippery and soapy feeling. Eye Contact ‐ stinging, watering of eyes, swelling of eyelids, intense pain, ulceration of eyes, loss of eyes or eyesight. Chronic: Symptoms associated with a chronic exposure vary greatly depending on the chemical. For example, the chronic effect of hydrochloric acid is damage to the teeth; the chronic effects of hydrofluoric acid are decreased bone density, fluorosis and anemia. First Aid: Inhalation ‐ remove person from source of contamination if safe to do so. Seek medical attention. Ingestion ‐ remove person from source of contamination. Seek medical attention and inform emergency responders of the name of the chemical swallowed. Skin Contact ‐ remove person from source of contamination and take immediately to an emergency shower or source of water. Remove clothing, shoes, socks, and jewelry from affected areas as quickly as possible, cutting them off if necessary. Be careful not to get any chemical on your skin or to inhale the vapors. Flush the affected area with water for a minimum of 15 minutes. Get medical attention. Eye Contact ‐ remove person from source of contamination and take immediately to an eyewash or source of water. Rinse the eyes for a minimum of 15 minutes. Have the person look up and down and from side to side. Get medical attention. Do not let the person rub their eyes or keep them tightly shut. Personal Protective Equipment: Always wear the proper gloves when working with corrosives. Neoprene and nitrile gloves are effective against most acids and bases. Polyvinyl chloride (PVC) is also effective for most acids. A Rev. 1.0 Dec 2020 Page 18 of 52 LABORATORY SAFETY MANUAL rubber coated apron and goggles should also be worn. If splashing is likely to occur, wear a face shield over the goggles. Always use corrosives in a chemical fume hood. 2.10 Reactives: General Characteristics: Polymerization Reactions Polymerization is a chemical reaction in which two or more molecules of a substance combine to form repeating structural units of the original molecule. This can result in an extremely high or uncontrolled release of heat. An example of a chemical which can undergo a polymerization reaction is styrene. Water Reactive Materials  When water reactive materials come in contact with water, one or more of the following can occur: liberation of heat which may cause ignition of the chemical itself if it is flammable, or ignition of flammables that are stored nearby; release of a flammable, toxic, or strong oxidizing gas; release of metal oxide fumes; and formation of corrosive acids.  Water reactive chemicals can be particularly hazardous to firefighting personnel responding to a fire in a lab, because water is the most commonly used fire extinguishing medium.  Examples of water reactive materials: Silanes Lithium, Sodium, Potassium Magnesium Zinc Aluminum Alkylaluminums Pyrophorics:  Pyrophoric materials can ignite spontaneously in the presence of air.  Examples of pyrophoric materials: Tert‐butyllithium Diethylzinc Triethylaluminum Rev. 1.0 Dec 2020 Page 19 of 52 LABORATORY SAFETY MANUAL Several organo metallic compounds. Peroxide Forming Materials:  Peroxides are very unstable and some chemicals that can form them are commonly used in laboratories. This makes peroxide‐forming materials some of the most hazardous substances found in a lab. Peroxide‐forming materials are chemicals that react with air, moisture, or impurities to form peroxides. The tendency to form peroxides by most of these materials is greatly increased by evaporation or distillation.  Organic peroxides are extremely sensitive to shock, sparks, heat, friction, impact, and light. Many peroxides formed from materials used in laboratories are more shock sensitive than TNT. Just the friction from unscrewing the cap of a container of ether that has peroxides in it can provide enough energy to cause a severe explosion.  Examples of peroxide‐forming materials (the italicized group is the more hazardous): Diisopropyl Ether Divinylacetylene Sodium Amide Potassium Amide Dioxane Diethyl Ether Tetrahydrofuran Vinyl Ethers Butadiene Vinylpyridine Acrylonitrile Styrene Other Shock Sensitive Materials: Chemicals containing nitro‐functional groups Hydrogen Peroxide (30% +) Ammonium Perchlorate Benzoyl Peroxide (when dry) Compounds containing the functional groups: acetylide, azide, diazo, halamine,nitroso,and ozonide. Use and Storage of Reactives:  A good way to reduce the potential risks is to minimize the amount of material used in the project. Use only the amount of material necessary to achieve the desired results.  Always substitute a less hazardous chemical for a highly reactive chemical whenever possible. If it is necessary to use a highly reactive chemical, order only the amount that is necessary for the work. Rev. 1.0 Dec 2020 Page 20 of 52 LABORATORY SAFETY MANUAL  Do not open the chemical container if peroxide formation is suspected. The act of opening the container could be sufficient to cause a severe explosion. Visually inspect liquid peroxide‐forming materials for crystals or unusual viscosity before opening. Pay special attention to the area around the cap. Peroxides usually form upon evaporation, so they will most likely be formed on the threads under the cap.  Store all peroxide‐forming materials away from heat, light, and sources of ignition. Light accelerates the formation of peroxides.  Secure the lids and caps on these containers to discourage the evaporation and concentration of these chemicals.  Never store peroxide‐forming materials in glass containers with screw cap lids or glass stoppers. Friction and grinding must be avoided.  Never distill ether unless it is known to be free of peroxides. Chemical containers in poor condition from Corrosion and crystal formation. Shock Sensitive Materials:  Store these materials separately from other chemicals and in a clearly labeled cabinet.  Never allow picric acid (Bouin’s solution) to dry out, as it is extremely explosive. Always store picric acid in a moist environment. Health Hazards Associated with Reactives: Rev. 1.0 Dec 2020 Page 21 of 52 LABORATORY SAFETY MANUAL Reactive chemicals are grouped as a category primarily because of the safety hazards associated with their use and storage and not because of similar acute or chronic health effects. For health hazard information on specific reactive materials consult the MSDS, the manufacturer. However, there are some hazards common to the use of reactive materials. Injuries can occur due to: heat or flames, inhalation of fumes, vapors, reaction products, and flying debris. First Aid: If someone is seriously injured, the most important step to take is to contact emergency responders as quickly as possible. Explain the situation and describe the location clearly and accurately. If someone is severely bleeding, put on protective gloves and apply a sterile dressing, clean cloth, or handkerchief to the wound. Then place the palm of your hand directly over the wound and apply pressure and keep the person calm. Continue to apply pressure until help arrives. If a person's clothes are on fire, he or she should drop immediately to the floor and roll. If a fire blanket is available, put it over the individual. An emergency shower, if one is immediately available, can also be used to douse flames. If a person goes into shock, have the individual lie down on their back (if safe to do so) and raise the feet about one foot above the floor. 2.11 Compressed Gas Cylinders: General Characteristics:  Cylinders of compressed gases can pose a chemical as well as a physical hazard.  If the valve of the cylinder breaks, the amount of force present could propel the cylinder through a brick wall. For example, a cylinder of compressed breathing air has the explosive force of 1 1/2 pounds of TNT. Use and Storage:  Whenever possible, use flammable and reactive gases in a fume hood or other ventilated enclosure.  Always use the appropriate regulator on a cylinder. If a regulator is not fit a cylinder's valve, replace the regulator. Do not attempt to adapt or modify a regulator to fit a cylinder it was not designed for. Regulators are designed to fit only specific cylinder valves to avoid improper use. Rev. 1.0 Dec 2020 Page 22 of 52 LABORATORY SAFETY MANUAL Properly attached regulator and safety cap  Compressed gas cylinders should be double chained to a stable structure. The first chain should be one third from the bottom of the cylinder and the second chain should be one third from the top of the cylinder Safety Cap not placed  Improper Inspect regulators, pressure relief devices, valves, cylinder connections, and hose lines way of securing frequently for damage. Proper way of securing cylinders cylinders  Do not use a cylinder that cannot be positively identified. Color coding is not a reliable way of identifying a cylinder because the colors can vary from supplier to supplier.  Do not use oil or grease on any cylinder component because a fire or explosion can result. Rev. 1.0 Dec 2020 Page 23 of 52 LABORATORY SAFETY MANUAL  Do not transfer gases from one cylinder to another. The gas may be incompatible with the residual gas remaining in the cylinder or may be incompatible with the cylinder material.  Never completely empty cylinders during lab operations. Leave approximately 25 PSI of pressure. This will prevent any residual gas in the cylinder from becoming contaminated.  Orient cylinders so that the main valve is always accessible and the name of the gas is visible.  Close the main cylinder valve whenever the cylinder is not in use.  Remove regulators from unused cylinders and always put the safety cap in place to protect the valve.  Oxygen should be stored in an area that is at least 20 feet away from any flammable or combustible materials (including gasses) or separated from combustibles by a non‐ combustible barrier at least 5 feet high and having a fire‐resistance rating of at least 1/2 hour.  To transport a cylinder, put on the safety cap and strap the cylinder to a hand truck in an upright position. Never roll a cylinder.  Always clearly mark empty cylinders and store them separately.  Be careful while handling compressed gas cylinders and never drop or strike a cylinder against anything.  Use only wrenches or other tools supplied by the cylinder supplier to open a valve.  Open cylinder valves slowly.  Only compatible gases should be stored together in a gas cylinder cabinet.  Do not store compressed gas cylinders in areas where the temperature can exceed 125F.  Never try to stop a leak between a cylinder and regulator by tightening the union nut unless the valve has been closed first.  Never strike an electric arc on the cylinder.  Never use a leaking, corroded or damaged cylinder. Remove the cylinder from service and contact the supplier for return. 2.12 Routs for Absorption of Chemicals and Prevention: All chemicals that have been discussed are poisonous. Indeed, nearly all substances are toxic to some extent. By adopting safe and careful working procedure lab personnel’s can minimize the risk of exposure to such substance. It is very important to know how chemicals enter into the Rev. 1.0 Dec 2020 Page 24 of 52 LABORATORY SAFETY MANUAL human body for their prevention. Some routs of adsorption of chemicals to human body are illuminated below. Ingestions (Through Mouth): This is fortunately not common in laboratories, but can occur through the accidental contamination of food drink or tobacco, by mouth suction of pipette and using crockery contaminated with chemical. In addition to the ingestion hazard associated with smoking, the vapors of many volatile compounds yield toxic products on pyrolysis when drawn through a lighted cigarette or pipe (e.g. carbon tetrachloride yields phosgene). Inhalation (into the lungs): This is a more common pathway for the absorption of toxic chemicals these may be in the form of gases, vapors, dusts or mists. It produces immediate effect on body. Prolong exposure to toxic gases, chemicals may lead to deadly consequences. Direct Absorption (Through skin): Chemicals readily absorb and damage the skin when contact with it. Liquids have greater penetration capacity then solids and gaseous chemicals. Repeated contact of solvents and other chemicals with the skin may lead to skin cancer, an unsightly and irritating skin disease which is often very hard to cure. In addition, sensitization to further contact or exposure may occur. Prevention:  When using such chemicals suitable protective equipments including gloves should be worn. Adequate protection of the eyes is absolutely essential and safety spectacles, or preferably goggles or a visor, must always be worn. When there is any possibility of inhalation of reactive vapors or dusts, all operations should normally be conducted in a fume cupboard. Additional protection may be provided by a gas mask or well‐fitting dust mask.  If any corrosive liquid or solid is spilled on the skin it should be immediately washed off with excess cold of water and then with soap if necessary.  Any spillages should be cleaned up without delay, preferably with the aid of sand. Flooding a spillage on a floor or bench with water is not always advisable if this is likely to spread the corrosive material and cause it to lodge in crevices and between floor‐boards. In cleaning up extensive spillage where toxic fumes are involved, full protective clothing including respirators should be used.  New thick rubber or plastic gloves should be worn after carefully checking that no holes are present. Skin burn must receive immediate and specialized medical attention. Rev. 1.0 Dec 2020 Page 25 of 52 LABORATORY SAFETY MANUAL  Protective gloves are often permeable to organic solvents and are easily punctured they should therefore be frequently inspected and replaced when necessary.  The use of solvents for washing spilled chemicals off the skin is best avoided since this may hasten the process of absorption through the skin. Every effort should be made by the laboratory worker to guard against these possibilities by adopting a rigorous approach to the avoidance of breathing all vapors and dusts, and of any contact between the skin and liquids or powders.  Every container should be labeled properly and every laboratory worker should obey these guiding principles. However, clean and careful working procedures are still necessary despite these precautions. Unit # 3 Working on Instruments In this technology driven world instruments play a crucial role in routine working of any quality control laboratory. FFC laboratory is well equipped with all contemporary instruments that are currently being used in the world. Working on such instruments entails two kinds of safety Rev. 1.0 Dec 2020 Page 26 of 52 LABORATORY SAFETY MANUAL Hazards: instrumental safety and personal safety. Safety associated with laboratory Instruments are discussed below: 3.1 Gas Chromatograph: Gas Chromatograph is very critical instrument of lab. All gas analysis is carried out on this instrument. Lab personal working on this instrument should be aware of the following safety measures: Instrument Safety:  When disconnecting plugs, pull on the plug, not its wires. Pulling on the wires may cause breakage.  Do not shut off column flow when the oven temperature is high it may damage the column.  Do not turn off carrier flow to a TCD detector while the detector is still “ON” it can damage the filament.  Do not inject water into the column it may damage the column.  Do not over heat the column.  Do not close the “online window” of the system it may cause to lose the unsafe data.  Do not open the column door while instrument is “ON”.  Do not mishandle the software of the system.  Provide suitable environment to the instrument. Avoid placing it in the damp, corrosive and dusty environment.  Do not use Hydrogen as carrier gas. Personal Safety:  Perform leak test on starting, installing new cylinder or connecting hydrogen generator to the instrument.  Turn off the oven and inlet/detector heated zones and allow them sufficient time to cool before servicing those areas. Wear protective gloves to service on components that have not fully cooled.  The inlets and detectors are insulated with a fibrous material that can cause irritation to the skin, eyes, and mucous membranes. Always wear gloves when working with the insulation. Additionally, if the insulation is flaky / crumbly, wear protective eyewear and a respirator. Rev. 1.0 Dec 2020 Page 27 of 52 LABORATORY SAFETY MANUAL  Turn off all gas supplies (especially hydrogen) before working on pneumatic areas of the instrument.  Wear eye protection when using compressed gases to dry or clean GC components.  Hydrogen gas is flammable and potentially explosive. When possible, turn off hydrogen gas when servicing detectors that use it. If this is not possible, make sure that either a column is installed in the oven or that the detector column fitting is capped. Otherwise the GC oven may fill with hydrogen and create an explosion hazard.  Do not use hydrogen to condition a column, it could vent into the oven and present an explosion hazard. Helium is preferred; however, nitrogen is adequate for packed columns.  Whenever possible, disconnect the GC from its power source before working on or near voltage carrying components of the GC.  The following components carry voltage when the GC is plugged in even if the power switch is off: ‐ The AC power cord ‐ The AC power supply  When the power to the GC is turned on, potentially dangerous voltages exist on these additional components: ‐ The power transformer ‐ All electronics boards ‐ All internal wires and cables connected to these boards. 3.2 Polarograph: Instrument Safety:  Carefully handle the dropping mercury electrode capillary.  Do not spill acid or caustic on to the key board of the instrument.  Adjust the nitrogen flow to 1.2 Kg. Personnel Safety:  Mercury used in Dropping Mercury Electrode is highly toxic.  Wear dust mask, gloves while handling the reaction vessel.  Keep wasted drop of mercury in sealed bottle containing water. 3.3 Kjeldahl Apparatus: Rev. 1.0 Dec 2020 Page 28 of 52 LABORATORY SAFETY MANUAL Instrument:  Do not fill digestion tube more than one sixth of it s capacity while digestion on digester.  Adjust the flow of water in scrubber do not allow to over flow it.  Regularly change the caustic in scrubber does not allow precipitation to form.  Do not wet the digestion while it is hot. Personnel Safety:  Always hold the digestion tube with the designated tong. 3.4 UV‐Visible Spectrometer: Instrument Safety:  Do not spill sample in the sample holder.  Handle sampling curettes carefully specially in MDEA and DEA analysis. Personnel Safety:  Wear UV light protective goggles while working on Spectrometer.  Wear chemical resistive gloves when toxic chemicals used. 3.5 Atomic Absorption Spectrometer: Instrument Safety:  Handle Hollow Cathode Lamp (HCL) carefully.  Inspect any blockage in burner head and remove it.  Use fresh demin. water every time. Personnel Safety:  Check any leakage before turning the flame on.  Turn on the exhaust prior analysis.  Do not exceed the flow of the gases from the standard limits.  Purge the gas lines before shutting the instrument off. Rev. 1.0 Dec 2020 Page 29 of 52 LABORATORY SAFETY MANUAL Unit # 4 Basic Emergency Measures and First Aid 4.1 Fire: Fire is a combination of three basic components i.e., Fuel, Oxidant and Ignition. Rev. 1.0 Dec 2020 Page 30 of 52 LABORATORY SAFETY MANUAL Fuel Any combustible material – solid, liquid or gas Ignition / heat Oxidant / Oxygen The energy necessary to The air we breathe is about increase the temperature of 21% oxygen – fire needs fuel to where sufficient vapors only 16% oxygen are given off for ignition to occur Each of these three elements must be present at the same time to have a fire. A fire will burn until one or more of the elements are removed. 4.2 Classes of Fire: Class A Ordinary combustibles or fibrous material, such as wood, paper, cloth, rubber, and some plastics. Class B Flammable or combustible liquids such as gasoline, kerosene, paint, Organic Solvent, paint thinners and propane Class C Energized electrical equipment, such as appliances, switches, panel boxes and power tools. Class D Rev. 1.0 Dec 2020 Page 31 of 52 LABORATORY SAFETY MANUAL Certain combustible metals, such as magnesium, titanium, potassium, and sodium. 4.3 Basic Awareness Fire Emergency: Every Lab. Personnel should  Check the location of fire alarms and know how they work.  Learn your building evacuation plan.  Know where your two nearest exits are located. Learn how doors swing and where stairs lead.  Make sure nothing blocks fire pulls, extinguishers and emergency exits.  Learn the sound of your building fire alarm.  Post emergency numbers (including security and first aid) near your telephone.  Make sure you know what to do if the fire alarm sounds. Plan your escape. When the fire is observed  Break the nearest “Fire Glass” to trigger fire alarm.  If there is no fire glass Dial 23 Emergency OR Alternate Number Emergency Number  Stay calm and be prepared to answer the operator’s questions regarding the emergency.  EVACUATE! When the fire alarm is ringing Rev. 1.0 Dec 2020 Page 32 of 52 LABORATORY SAFETY MANUAL  Leave at once, taking direction from the emergency warden.  Do not delay yourself by gathering personal items. Your safety always comes first.  Before you open any door, feel the door with the back of your hand. If the door is cold, slowly open it.  Get out quickly using designated fire exits. If you are trapped in smoke or heat  Before you open any door, feel the door with the back of your hand. If the door is warm to the touch, DO NOT attempt to open the door.  Block the cracks around doors with towels, rags, clothing or tape, and cover vents to keep out smoke.  Stay low to the floor, and if possible, cover your mouth and nose with a damp cloth or dust mask to help you breathe.  If there is a phone in the room where you are trapped, call the fire department to tell them exactly where you are located.  Wait at a window and signal for help. Do not panic or jump!! WAIT!  If possible, open the window at the top or bottom, but do not break it, you may need to close the window if smoke rushes in.  Be patient. Rescuing all the occupants of a building can take several hours. 4.4 Fire Fighting BEFORE you consider fighting a fire...  Confirm that the fire is small and is not spreading.  Call the fire department.  Confirm you have a safe path to an exit not threatened by the fire.  You know what kind of extinguisher is required and the correct extinguisher is immediately at hand. NEVER fight a fire if...  The fire is spreading beyond the immediate area in which it started, or if it is already a large fire.  The fire could block your escape route.  You are unsure of the proper operation of the extinguisher. Rev. 1.0 Dec 2020 Page 33 of 52 LABORATORY SAFETY MANUAL  You doubt that the extinguisher you are holding is designed for the type of fire at hand or is large enough to fight the fire. Identification of Fire Extinguishers Every fire extinguisher is specific for specific class of fire. It is labeled on the cylinder for which class of fire it is used for. Many extinguishers are available today that can be used on different types of fires, e.g. A‐B, B‐C, or A‐B‐C. New Style of Labeling This label shows that this extinguisher can be used on ordinary combustibles (A) or flammable liquids (B). The red slash through the last symbol tells you that the extinguisher cannot be used on electrical fires (C). Use and Handling of Fire Extinguisher  Use when fire is on small scale!  Check the rating on Fire Extinguisher A, B, C or D.  Evacuate Area and call Safety/Fire Department IF YOU FIGHT A FIRE, REMEMBER THE WORD PASS PULL... AIM... SQUEEZE... SWEEP PULL... the pin. Some extinguishers require releasing a lock latch, pressing a puncture lever or other motion. Rev. 1.0 Dec 2020 Page 34 of 52 LABORATORY SAFETY MANUAL AIM... low, pointing the extinguisher nozzle (or its horn or hose) at the base of the fire SQUEEZE... the handle. This releases the extinguishing agent. SWEEP... from side to side at the base of the fire until it appears to be out. Watch the fire area in case fire breaks out again, and repeat use of extinguisher if necessary. 4.5 First Aid: It is emergency treatment given to an injured, drowning unconscious, or suddenly ill person before professional medical help arrives. Emergency Measures  Do not move an injured person (particularly if the injuries are the result of fall, crash or other violence. Unless it is absolutely necessary to save him from further danger, do not turn, lift or manipulate him. If he has been injured internally or his spine is broken, unnecessary movement may kill or cripple him.  Act fast if the victim is bleeding severely or if he has swallowed a chemical or if he has stopped breathing because of gas poisoning or electric shock. Every second counts. A person may die within three minutes after breathing stops, unless given artificial respiration.  In real world, life threatening emergencies are rare. In most cases you can start with this step: Keeps the person lying down quietly. If he has vomited there is no danger that his neck is broken ‐ turn his body and head to side to prevent choking. Keep him warm with blankets, but do not over heat apply external heat. Rev. 1.0 Dec 2020 Page 35 of 52 LABORATORY SAFETY MANUAL  Summon medical help. If possible get someone to telephone a doctor while with the person, keeping him quiet and warm and preventing his chocking. The doctor should be told the nature of the emergency and asked what steps to be can be taken immediately.  Examine the person gently. Cut his clothing, if necessary to avoid movement or added pain but do not pull clothing away from burns.  Re‐assure the person, and try to be calm. Your calmness can allay his fear and panic. Such reassurance may lesser shock and fasten recovery.  Do not give fluids to unconscious person fluids may enter his windpipe and cause suffocation. Do not try to rouse an unconscious person by slapping shaking or shouting. Bleeding and Hemorrhage A severe cut or wound is dangerous because of the possibility of great loss of blood. The simplest and most effective method to stop bleeding is by direct pressure on the wound with a gauze pad. Apply direct pressure on and around. It will in most cases cause the bleeding to stop. It is important to apply constant pressure. Do not keep dabbing at the wound and lifting the gauze every few seconds to see if bleeding has stopped. This will irritate the wound and prevent the blood from clothing. The only time pressure should be removed is when the blood has soaked through the gauze completely, requiring a fresh pad. If no blood soaks through, you can then bind the gauze or pad firmly over the wound with tape or strips of cloth. If the bleeding occurs because of a deep cut in an arm or leg, uncomplicated by other injuries raising the limb very high helps to control bleeding because there is less blood flow into an elevated limb. There are three types of bleeding. Arterial, Venous and Capillary. Arterial: bleeding is the most serious. It is sometimes difficult to stop because the flows so fast that clot cannot form. Blood from an artery comes in spurts; caused by the heartbeat an arterial blood is red in color (rich in oxygen). Venous: Blood from a vein comes in‐a steady flow and tends to be darker in color, often bluish red. Capillary: Bleeding from capillaries generally results from minor injury. It is rarely serious and usually clots quickly. Pressure Point In both arterial and venous bleeding, the best treatment is direct pressure on and around the wound. Sometimes, however, this does not stop arterial ‘bleeding’. Rev. 1.0 Dec 2020 Page 36 of 52 LABORATORY SAFETY MANUAL The tourniquet Another method of stopping bleeding is the application of a tourniquet, as described in the steps listed below. The two places to apply a tourniquet are (a) The width of a hand from the armpit for bleeding from the arm. (b) The width of a hand below the groin of bleeding from the thigh or leg. 1. Use several thickness of the gauze or cloth to make pad. 2. Use a wide flat strip of fabric long enough to go twice around the limb. 4. Tie the fabric with a half‐hitch. Insert a small stick and tie again with a reef‐knot. 5. Tighten the tourniquet by twisting the stick. Do not twist too hard. You will know the tourniquet is tight enough when the bleeding stops immediately, if a tap had been turned off. 6. Every ten minutes, loosen the tourniquet for one minute to let the blood circulate in the limb, while the tourniquet is loose, apply pressure by hand against the wound. If new bleeding does not start again during that one minute, do not retighten the tourniquet; but leave it place, in case heavy bleeding does occur. 7. If you can mark fabric with the time that the tourniquet was first place, this information will be useful to the doctor. Leave the tourniquet uncovered so that it can be seen by any doctor or aid worker who arrives, and so that you can get it. Breathing and Chocking Problem You must act fast if breathing is plainly difficult, or if a person does appear to be breathing at all. Remember, even if breathing stops, the heart continues to beat for a few minutes; quick action may save a life. Apply artificial respiration after electric shock, apparent accident that causes the breathing to stop. Quickly explore the mouth for any obstruction. Mud, sand, or displaced false, teeth, for example that would interfere with the passage of air. Loosen any tight clothing about the neck and chest. Continue artificial respiration until a doctor advises you to stop. It has found in cases of stoppage of breathing from electric shock that victims recovered even several hours after artificial respiration has been started. In these victims the lungs are clear, but the respiration control centre the brain has been paralyzed temporarily. The mouth to mouth method is now recommended as the most effective, least complicated, means of artificial respiration. Rev. 1.0 Dec 2020 Page 37 of 52 LABORATORY SAFETY MANUAL Artificial Respiration This is a technique of artificial respiration by which the rescuer's breath goes directly into the victim's lungs. It is the easiest, most practical, most efficient method. If you use this technique, place the victim on his back and tilt his head so that the chin points upward. Open the jaw into a jutting out position. Open your own mouth wide and place it tightly over the victim's at the same pinching his nostrils shut. If his mouth is injured or completely clenched place your mouth over his nose, making certain that his mouth is closed. Blow into the victim's mouth or nose. Remove your mouth and listen for the outward rush of air which indicates adequate air exchange. If there is no return of air check for any obstruction that can be removed by a gentle sweep of your fingers. If the victim's tongue is in the way, carefully pull it forward. For an adult a blow vigorously at about twelve breaths per minute. Electric Shock If the victim is in contact with electricity (through a high tension, any other type of wire or a defective home appliance) use a non‐conductor, such as stick, rolled up dry newspaper, or heavy, dry gloves rubber, if available to pull him away from the source of current as quickly as you can. Push the wire off the body of the victim with a dry stick. Stand on dry place. Electricity passes easily through moist articles and metals. Avoid touching the person directly until he is away from the source of shock. Severe electric shock may paralyze the respiratory centre in the brain and upset the natural rhythm of the heart. Once the victim is separated from the source of electricity. Use mouth‐to‐ mouth artificial respiration to restore breathing. If the heart has stopped or is beating irregularly, apply closed chest heart massage. If he is breathing normally keep him warm and in a half sitting position until medical help arrives. Shock should not be confused with fainting. It usually follows an accident especially a painful one, or one involving the loss of blood. When a person goes into shock, he becomes pale, and his skin feels cold and clammy. He breathes rapidly and his pulse beats faster and faintly. He may become partly or completely unconscious. The rapid, weak pulse and cold, clammy skin of the person in shock are not usually seen in people who have only fainted. Prevention of Shock/ Speeding up the Recovery  Keeps the victim lying quietly with his feet higher than his head. Cover him with warm blankets. It is unnecessary to keep the victim very warm too much heat may be harmful. Rev. 1.0 Dec 2020 Page 38 of 52 LABORATORY SAFETY MANUAL  If the victim is fully conscious, give him something to drink, especially a drink containing salt or sugar. Orange juice, or a glass water containing, teaspoonful of salt is beneficial. Do not give any fluid if the person has suffered a possible abdominal injury.  Remember that prolonged, severe shock may kill. Usually, the severe shock that follows a major hemorrhage, an automobile accident, or major burn will require transfusions of blood. You can best help to prevent the fatal action of shock by stopping any bleeding and relieving pain such as may be caused by a fracture by applying the proper splints. Talk reassuringly to the victim and hold his hand. This may rally his vital forces enough to delay the onset of shock. Burns If the clothes or hair catch fire, pour water, milk, or any other non‐flammable liquid on the victim. Do not take time to hunt for fluids if more is available. Take a coat, rug or other heavy material, cover the flames and smoother them. A burn is an injury to the skin, but it may also involve and even destroy the tissues under the skin. The degree of a burn depends on how deep it goes. In minor (first degree) burns, the skin is red but unbroken, and there is no danger of infection. Second and third degree burn involve the entire thickness of the skin. Fourth degree burns involve tissues under the skin. These burns easily become infected. Shock is a more immediate danger than infection if the burn is a major one. The seriousness of a burn depends on both its depth and the area it covers. Even a superficial burn dangerous if it covers more than about 10‐15% of the body's surface. The victim of deep or extensive burns should be wrapped gently in a sheet or blanket and moved to a hospital without delay. If this is not possible, immerse the burnt area in cold water, or put the victim (with his clothes on) in a tub.full of lukewarm running water. This will relieve the pain and help to prevent shock. Additional preventions against shock should be taken. Do not try to pull off clothing or any foreign particles that stick to the burnt area. Do not puncture blisters. Do not apply cream or any medication to a major burn. If it is not possible to nurse the burn in cold water, have the person be on a clean sheet. Protect burnt areas with a dressing of sterile gauze or clean cloth (not paper tissues), and keep the person warm under a blanket until medical help arrives. A mild pain‐killer (such as aspirin) may be given, but keep a record of it for the doctor. For minor burns, run cold water over the affected area to relieve the pain. If you have an antiseptic ointment that also has anesthetic properties, use it. Do not use greasy ointments or Rev. 1.0 Dec 2020 Page 39 of 52 LABORATORY SAFETY MANUAL substances such as butter or cold cream. Although grease gives relief by keeping air from the burns, it is hard to wash off also lead to infection. Eye Contamination Cinders, grit, dirt or any other foreign bodies in the eyes are best removed by washing the affected eye liberally with clean water or a salt solution that is made by adding a level teaspoonful of salt to a pint of warm water. Use a clean dropper. If this procedure does not work, you may try direct removal when the particle plainly visible and not imbedded in the eyeball. Make certain the light is good. Better still if possible use a flashlight in a dark room to search for the object. You can dab gently over the eyelid, using a bit of cotton wrapped around a toothpick or match‐ stick. If the pain persists, it would be better to go to a doctor or the nearest hospital to have the particle removed. Do not rub the eye. If you are far from a doctor or first aid station, and are confronted with a foreign body under the lid, you may be able to remove the object by one of the following techniques: a) Pull the upper lid down and out causing the eye to water the foreign object to washed out. b) That failing have the person roll his eyeball upward, and search for the object under the lower lid. c) If this fails, pullout and up on the upper lid; place a smooth matchstick above the margin of the lid while the person is looking up. Have him look down, and quickly flip back the lid over the stick. If the foreign object can be seen, it may be carefully removed with the end of a soft, clean handkerchief. Caution Never attempt to remove anything embedded in the eyeball. Instead, get the person to a source of medical help as quickly as possible. Rev. 1.0 Dec 2020 Page 40 of 52 LABORATORY SAFETY MANUAL Unit # 5 Safe Laboratory Practices 5.1 Avoid of Routine Exposure All prudent efforts shall be taken to minimize chemical exposures. Engineering controls ventilation systems, laboratory hoods, remote handling systems, etc.), Administrative controls (limited use of materials, substitution of less hazardous materials, procurement controls, proper handling procedures, appropriate training, etc.), and personal protective equipment (PPE) will be used to minimize employee exposure to all chemicals. Wear gloves, aprons, and face/eye protection when possible to prevent skin contact. Use the least toxic chemical that the task requires. The use of listed carcinogens or other highly toxic chemicals shall be avoided if at all possible. Test methods requiring these chemicals shall be reviewed to determine if a less toxic compound can be used. Solvents such as benzene, acetone, xylene, or trichloroethylene should not be used for routine cleaning purposes. Rev. 1.0 Dec 2020 Page 41 of 52 LABORATORY SAFETY MANUAL Develop and encourage safe chemical handling habits.  Avoid unnecessary exposure to chemicals by any route.  Do not smell, taste, or allow chemicals to touch your skin.  Plan work with chemicals to minimize exposure. Whenever possible, conduct laboratory procedures or testing that releases hazardous materials under a laboratory exhaust hood. If this is not possible, use a local exhaust system or other means to control and remove the hazardous contaminants from the lab.  Vent laboratory apparatus that may discharge toxic chemicals (vacuum pumps, distillation columns, etc.) into an exhaust hood or other appropriate exhaust devices.  Inspect protective equipment before use. If relying on a ventilation system for protection, ensure system is operating properly before starting work.  Wear all required Personal Protective Equipment (PPE).  Clean and store PPE properly after use. 5.2 Choice of Chemicals Whenever possible, select the chemicals that will be used based on minimizing exposure. Use chemicals with lower evaporation rates and vapor pressures. Determine if the available ventilation system is adequate to control exposures. 5.3 Eating, Drinking, Smoking To minimize the potential for eating/drinking hazardous materials, the following procedures will be followed in all Caltrans laboratories:  No eating, drinking, smoking, gum chewing or application of cosmetics in areas where chemicals are stored or used.  Wash hands and face after working with or around chemicals and before eating, drinking, smoking, using the restroom, applying cosmetics, or leaving the facility.  Do not store, handle, or prepare food or beverages in refrigerators, glassware, utensils, microwaves, ovens, cabinets, inks, countertops, tables, or other locations which are also used for laboratory operations. Food and drink is permitted only in designated eating, preparation, and food storage locations within the lab.  Do not enter designated eating, preparation, and food storage areas wearing contaminated clothing or with contaminated laboratory tools or equipment. If in doubt, remove or clean equipment and clothing before bringing it into these areas. Rev. 1.0 Dec 2020 Page 42 of 52 LABORATORY SAFETY MANUAL 5.4 Equipment and Glassware Handle and store laboratory glassware with care to avoid damage.  Do not use damaged glassware.  Use extra care with Dewar flasks and other evacuated glass apparatus. Shield or wrap them to contain chemicals and fragments should implosion occur.  Use equipment only for its designed purpose. Do not use juryrigged or makeshift devices or equipment.  Do not use equipment without safety guards and devices in place and operational.  Always follow manufacturer’s instructions.  Do not operate equipment or machinery unless trained to do so.  If unsure, ask supervisor for direction before proceeding. 5.5 Decontamination To minimize the hazard of residual chemicals, always cleanup your work area after completing test procedures or laboratory work. Wipe up any spills or waste material and dispose of properly. Clean tools and containers that may be contaminated before putting them away. Clean any protective equipment that may have been contaminated and store properly. After protective equipment has been removed, check personal clothing for contamination. Remove or neutralize contamination or contaminated clothing before leaving the laboratory or going home. Always wash face and hands before leaving. 5.5 Horseplay Avoid practical jokes or other behavior that might confuse, startle or distract another worker. Never use laboratory chemicals, materials, or equipment for practical jokes or horseplay. 5.6 Mouth Suction Do not use mouth suction for pipettes or starting a siphon. 5.7 Personal Apparel To minimize the hazards of entanglement or chemical contamination the following personal apparel rules will be followed: Rev. 1.0 Dec 2020 Page 43 of 52 LABORATORY SAFETY MANUAL  Confine long hair, necklaces, neckties, and other loose clothing that could get caught in moving equipment or be contaminated with chemicals.  Remove jewelry, rings, earrings, watches, and other personal items that will interfere with the use of protective equipment or could get caught in equipment.  Safety shoes should be worn at all times in the chemical and material handling and storage areas of the laboratory. Sandals, flip flops, or open toed shoes are not allowed, especially in the chemistry laboratory. 5.8 Personal Housekeeping  Keep the work area clean and uncluttered.  Keep chemicals and equipment properly labeled and stored.  Cleanup the area on completion of an operation or at the end of the day. 5.9 Personal Protective Equipment (PPE) The most important thing to remember about protective clothing is that it only protects you if you wear it. The lab supervisor must ensure that appropriate personal protective equipment is worn by all persons, including visitors, in areas where chemicals are stored or handled. Material Safety Data Sheets or other references should be consulted for information on the type of protective clothing required for the particular work you are performing. In general, when working in an area with hazardous materials, your skin should be covered from shoulders to toes. Goggles  Goggles provide the best protection against chemical splashes, vapors, dusts, and mists. Rev. 1.0 Dec 2020 Page 44 of 52 LABORATORY SAFETY MANUAL  Goggles that have indirect vents or are non‐vented provide the most protection, and an anti‐fog agent can be applied.  Standard safety glasses provide protection against impact.  Remember, prescription glasses do not provide adequate protection in a laboratory setting. Prescription safety glasses can be purchased from most opticians.  Alternatively, safety glasses and goggles designed to fit over prescription glasses are available through commercial vendors. Face shields  Face shields can protect against impact, dust, particulates, and splashes to the face, eyes, and throat. However, always wear protective eyewear such as goggles underneath a face shield. Chemical vapors and splashes can still travel under and around a face shield.  If scratches or cracks are noticed in the face shield, replace the window. Protective Gloves Rev. 1.0 Dec 2020 Page 45 of 52 LABORATORY SAFETY MANUAL  Any glove can be permeated by chemicals. The rate at which this occurs depends on the composition of the glove, the chemicals present and their concentration, and the exposure time to the glove. If you are not certain which type of glove provides you with the protection you need, contact the manufacturer and ask for specifics on that glove.  If direct chemical contact occurs, replace gloves regularly throughout the day. Wash hands regularly and remove gloves before answering the telephone or opening doors to prevent the spread of contamination.  Check gloves for tears, holes and cracks.  Butyl, neoprene, and nitrile gloves are resistant to most chemicals, e.g., alcohols, aldehydes, ketones, most inorganic acids, and most caustics.  Disposable latex and vinyl gloves protect against some chemicals, most aqueous solutions, and microorganisms and reduce risk of product contamination.  Leather and some knit gloves will protect against cuts, abrasions, and scratches, but not against chemicals.  Temperature‐resistant gloves protect against cryogenic liquids, flames, and high temperatures such as autoclaves. Note: Latex gloves should not be worn if a person has or suspects a latex allergy. Lab Coats / Aprons  The primary purpose of a lab coat is to protect against splashes and spills. A lab coat should be nonflammable, where necessary, and should be easily removed. Other types of lab coats such as flame resistant coats are available.  Lab coats should be buttoned when in use. Rev. 1.0 Dec 2020 Page 46 of 52 LABORATORY SAFETY MANUAL  Rubber coated aprons can be worn to protect against chemical splashes and may be worn over a lab coat for additional protection. Safety Shoes Shoes that fully cover the feet should always be worn in a lab. If work is going to be performed that includes moving large and heavy objects, steel‐toed shoes should be worn. Respirators Use respirators when going into the area where there is a risk of leakage of toxic gases 5.10 Unattended Operations  Leave lights on.  Place an appropriate sign on the door.  Provide for containment of hazardous substances in the event of failure of a utility service (such as cooling water) to an unattended operation. 5.11 Use of Fume Hoods Use a fume hood for all procedures that might result in the release of hazardous chemical vapors or dust.  Confirm that the hood is working before use by holding a Kim wipe, or other lightweight paper, up to the opening of the hood.  The paper should be pulled inward.  Leave the hood "on" when it is not in active use if toxic substances are stored inside or if it is uncertain whether adequate general laboratory ventilation will be maintained when it is "off." Rev. 1.0 Dec 2020 Page 47 of 52 LABORATORY SAFETY MANUAL Proper Use of Fume Hoods  Equipment and other materials should be placed at least six inches behind the sash, preferably in the middle of the hood. This will reduce the exposure of personnel to chemical vapors that may escape into the lab due to air turbulence.  When the hood is not in use, pull the sash all the way down. While personnel are working at the hood, pull down the sash as far as is practical. The sash is constructed of safety glass to protect users against fire, splashes, and explosions.  Fume hood sash should be at or below 18 inches.  Do not keep loose papers, paper towels, or tissues (e.g., Kim wipes®) in the hood. These materials can be drawn into the blower and adversely affect the performance of the hood.  Do not use a fume hood as a storage cabinet for chemicals. Work with the fume hood sash down as Improper use of the fume hood far as practical  Excessive storage of chemicals and other items will disrupt the designed airflow in the hood. In particular, do not store chemicals against the baffle at the back of the hood, because this will interfere with the laminar airflow across the hood.  If large equipment must be kept in a fume hood, raise it 1.5 inches off the work surface to allow air to flow underneath. This dramatically reduces the turbulence within the hood and increases its efficiency. UNSAFE Rev. 1.0 Dec 2020 Page 48 of 52 LABORATORY SAFETY MANUAL  Do not place objects directly in front of a fume hood (such as refrigerators or lab coats hanging on the manual controls) as this can disrupt the airflow and draw contaminants out of the hood.  Keep in mind that modifications made to a fume hood system, e.g., adding a snorkel, can render the entire system ineffective. Modifications should not be done without proper authorization.  Minimize the amount of foot traffic immediately in front of a hood. Walking past hoods causes turbulence that can draw contaminants out of the hood and into the room. 5.12 Vigilance Be alert to unsafe conditions and see that they are corrected when detected. 5.13 Waste Disposal  Waste shall be placed in clearly labeled containers appropriate for such containment.  Reaction residues, toweling, etc., shall be placed in a separate container clearly labeled and approved for such containment.  Containers shall be removed from the laboratory and properly disposed of as soon as possible after completion of testing and subsequent shift.  Containers which must be kept in the laboratory overnight shall be placed in a locked room designated and approved for overnight storage of such materials.  A sign stating that particularly hazardous materials are being stored in the room must be posted in the area and be clearly visible to personnel approaching the room whenever such materials are contained therein. 5.14 Notification Employees must notify the laboratory supervisor when  There is a failure of any of the equipment used in the process, especially safeguards such as fume hoods or clamped apparatus. There are unexpected results.  Members of the laboratory staff become ill, suspect that they or others have been exposed, or otherwise suspect a failure of any safeguards. 5.15 Visitors Rev. 1.0 Dec 2020 Page 49 of 52 LABORATORY SAFETY MANUAL All visitors allowed into the work area shall wear appropriate safety equipment. 5.16 Signs, Labels, Hazard Identification Signs and labels help communicate important health, safety, and chemical hazard information to employees. Caltrans shall utilize the National Fire Protection Association (NFPA) hazard labeling system. Whenever chemicals are being used in the workplace, it is the responsibility of every worker to:  Read labels before handling container and follow their warnings.  Make sure that every container of a chemical has a label.  Report missing, dirty, or illegible labels so they can be replaced.  Put labels on transfer containers for all chemicals.  Ask the laboratory supervisor about any label information that is not understood. Signs Prominent signs of the following types should be posted:  Emergency telephone numbers.  Location signs for safety showers, eyewash stations, other safety and first aid equipment, fire extinguishers, exits, and areas where food and beverage consumption and storage are permitted.  Warnings at areas or equipment where special or unusual hazards exist.  Warnings that unauthorized personnel are not allowed in the laboratory and that safety equipment (safety glasses as necessary) are required in the laboratory. Labels  Each original container of chemicals in the workplace is to be labeled, tagged, or marked with information giving the identity of the chemical, the appropriate hazard warnings, and the name and address of the manufacturer.  The identity can be any chemical or common name designated for the individual chemical or mixture, as long as the term used is the same as on the MSDS. If the manufacturers label lists the hazard codes on the container, no other label is required. If the chemical is transferred to another container, it is to be relabeled with the correct ID and hazard code.  Use a MSDS and/or other published data to assign the appropriate values (0, 1, 2, 3, and 4) for each of the three NFPA hazard categories (Health, Fire, and Reactivity). The value 0 corresponds to minimal hazard and 4 to extreme hazard. Rev. 1.0 Dec 2020 Page 50 of 52 LABORATORY SAFETY MANUAL  If a chemical substance is produced for commercial purposes by another user outside of the laboratory, the employer shall comply with the Hazard Communication Standard for the requirements for preparation of material safety data sheets and labeling. Hazard Identification A chemical shall be considered hazardous if it poses a physical hazard, health hazard, or is listed on the Cal‐OSHA Directors List of Hazardous Substances. It is important to realize that the determination of occupational health hazards is complicated by the fact that symptoms occur commonly in non‐occupationally exposed populations Hazard Codes and Labeling (NFPA) Rev. 1.0 Dec 2020 Page 51 of 52 LABORATORY SAFETY MANUAL Using a MSDS and/or other published data, appropriate values (0, 1, 2, 3 or 4) are assigned for each of the other three NFPA hazard categories: Health, Fire, and Reactivity: Health = BLUE Special Hazards Fire = RED C = Chronic Health Reactivity = YELLOW W = Water Special = WHITE Reactive X = Oxidizer Rev. 1.0 Dec 2020 Page 52 of 52