Lab-scale process safety management

Abstract

The U.S. OSHA Laboratory Standard and Hazard Communication Standard have improved safety management in laboratories and pilot plants. In spite of these standards, incidents which result in injuries and property loss continue to occur in these research and teaching locations. Application of the methods outlined in the OSHA Process Safety Standard to laboratory and pilot plant operations has the potential to further reduce the risks associated with the operations in these locations. In particular, a Lab PSM Approach to hazard recognition and assessment, to the development of standard operating procedures, and to the management of change will provide significant guidance to researchers and educators in safety management. Application of Process Safety Management to the operations in these locations is examined and the benefits of the approach are discussed.

Should science departments have their own safety personnel? – An assessment of a centralized approach

“…6 It therefore became necessary to assess the present state of affairs. In doing this assessment some of the major parts of the standard were reviewed with a view to moving swiftly, creatively and as painlessly as possible in a cost-effective manner towards compliance once the standards are in place.…”

Managing Process Hazards in Lab-Scale Pilot Plant for Safe Operation

“…It is, therefore, not surprising to know that rate opportunity of lab accident in schools and colleges is 100-1000 times greater than at Dow or DuPont as estimated by James Kaufman (Banderly, 2009). Three examples of the accidents at pilot plant are summarized by Langerman (2009) including phosphorous oxychloride release due to gasket had failure which causes inhalation injuries of the technician, cumene hydroperoxide detonation due to the inefficient heat transfer of catalytic reactor which destroy the pilot plant and the release of hot tetrahydrofuran and odium potassium catalyst due to reflux apparatus failure which immediately ignite upon contact with air. It was resulting fire destroyed part of one laboratory and caused water and smoke damage throughout the building.…”

“…Investigation of the pilot plant incidents reveals that the underlying causes are similar to those found in real process plant accidents and should be addressed by applying the established guiding principle of OSHA Process Safety Management (PSM) to these facilities (Langerman, 2009). OSHA PSM is designed to provide the specific guidance needed to manage operational safety, particularly related to process hazards without excessive operational interference.…”

“…Process Hazards Management (PHA) CFR 1910.119 (e) is one of the OSHA PSM elements, focusing on process hazards management (OSHA, 1992). Langerman (2009) indicates that application of PHA approaches to manage process hazards associated with the operations in the labs have a potential to provide the excellent guidelines with the reduction of incidents and losses. Review of the above issues shows that the underlying causes should be addressed by applying the guiding principles of PHA to lab-scale pilot plants.…”

Joint applicability test of software for laboratory assessment and risk analysis

“…Various solutions were presented in the literature (Kremer et al 2009, Langerman 2009Leggett 2012. However, those methods are still too specialized to serve as a universal risk analysis method for academic research and teaching laboratories (Pluess et al 2013).…”