Chemical Safety

Chapter 3: Standard Operating Procedures

This document represents a minimum set of guidelines for the handling of toxic chemicals on campus. Individual administrative units, laboratories, or research groups are expected to develop more detailed procedures as their situations warrant. Safety references such as those listed in Appendix 3 of this document may be useful in developing additional procedures. As outlined in the Campus Administrative Manual, supervisors and principal investigators are responsible for complying with and/or enforcing appropriate safety and hygiene measures in the work areas they supervise. The Division of Research Safety (DRS) is available for consultative assistance to develop safe procedures for situations not covered in this guide.

Some rules or standard operating procedures, which apply to all work areas on campus, include the following:

3.1 General Procedures

Respect and understand the safety and health hazards associated with the chemicals and equipment you use, and practice the following general safety guidelines at ALL times:

Accident response: If an injury requiring emergency medical assistance has occurred, call 9-911. You may obtain 9-911 stickers from the Division of Public Safety at 333-1216. See Chapter 5 for more information.

Chemical spills: If a toxic/hazardous chemical has made contact with the skin, start flushing the area immediately. If emergency assistance is required, call 9-911. Cleanup procedures for chemical spills are presented in Chapter 6.

Children and unauthorized persons: Children and other unauthorized persons should not be in laboratories where hazardous materials or hazardous equipment are being used.

Disposal of chemicals: Requests for collection of chemical waste must be submitted in writing as outlined in the University of Illinois at Urbana-Champaign Chemical Waste Management Guide. Questions about chemical waste management should be directed to the Chemical Safety Section of DRS at (217) 333-2755. A list of DRS-prepared resource materials that address common chemical waste issues is found in Appendix 2.

Electrical: Access to electrical equipment (e.g. plugs, switches and electrical panels) should be maintained free from obstructions to allow immediate access in an emergency. All receptacle outlets in laboratory spaces should be the polarized grounding type. Ground Fault Circuit Interrupters (GFCI's) should be used in those locations involving wet processes or outdoor work, including electrical outlets within six feet of sinks. All electrical hand tools used inside laboratories should be grounded or double insulated.

All electrical extension cords used should be visible and inspected on a periodic basis for damage and/or defects. Cords should not run in aisles or corridors where they might be damaged or create a tripping hazard. Cords should not be run through doors, walls or partitions, under rugs, or above dropped ceilings. They should not be wrapped around fixtures, tied in knots, or draped over pipes, lights, or ventilation ductwork.

Extension cords should not be used as substitution for fixed receptacle outlets. Cords used for 110-120 volt service should be UL listed standard heavy-duty three-wire equipped with a polarized three prong plug. Two-wire type extension cords should not be used.

Emergency eye wash/safety showers: Be certain safety showers/emergency eye washes are properly located and maintained. These units should be located in areas which will be immediately accessible (reachable within 10 seconds). There should be no obstructions that might inhibit the use of this equipment.

Eye washes and safety showers should be flushed on a regular basis to verify that the units are working and to clear the lines of stale water and debris. Whenever these emergency units are checked for proper functioning, written documentation showing the date and person's initials performing the check, should be maintained.

Equipment: Use proper equipment that is in good condition. For example, never use chipped or cracked glassware. Shield pressurized or vacuum apparatus and safeguard against bumping or overheating.

Fire extinguishers: Fire extinguishers must be available, charged, and hung in a location which is immediately accessible (reachable within 10 seconds). There should be no obstructions that might inhibit the use of this equipment. Make sure that all extinguishers are checked annually. Each extinguisher should have a tag indicating the date it was last checked. Contact DRS (217) 333-2755 for assistance.

Food, drink, cosmetics: Eating, drinking and the application of cosmetics are forbidden in areas where hazardous chemicals are used and should be done only in well-defined, designated non-chemical areas. Do not store food in the same refrigerator with chemicals, biohazards or radioactive materials.

Horseplay: Practical jokes or other behavior which might confuse, startle, or distract, another worker is forbidden when hazardous chemicals are present.

Housekeeping: Exits, aisles and safety equipment must NOT be obstructed in any way with equipment, furniture, or other items. Aisles within the laboratory should be 36 inches in clear width. Work areas and floors are not to be used for excessive storage. Doors which are not in use but which are accessible from a corridor or adjacent room should be appropriately labeled if they are blocked on the interior of the room. Hallways are not to be used as storage areas. Refer to Campus Administrative Manual (CAM) V/B - 6.2, Departmental Use of Corridors. Items may be stored in corridors only if prior approval is obtained from the Office of Project Planning and Facilities Management (333-1232).

Mercaptans: To avoid false reporting of natural gas leaks, mercaptans should not be used in such a manner (e.g. scrubbers for effluent) that persons outside of the laboratory could smell the mercaptan and suspect a natural gas leak in the building. All persons using mercaptans should report these uses to the campus telecommunicators (3-1216) prior to actual use.

Mouth pipetting: Mouth pipetting is forbidden.

Perchloric acid: If perchloric acid is heated above ambient temperature it may evaporate and condense on ductwork in the form of explosive perchlorates. Hence, when heating perchloric acid above ambient temperature, a perchloric acid fume hood with a water wash down system or a local scrubbing or trapping system must be used.

Signs: Laboratories where hazardous materials or operations are present must follow the University of Illinois at Urbana-Champaign Laboratory Signage Guideline. An emergency contact card, updated at least annually, should be posted on each laboratory entrance. A recommended form with the information needed by emergency responders is available in Appendix 7.

Smoking: No smoking in laboratories. If you have been using chemicals, be sure to wash your hands before smoking.

Spill preparedness: Before working with chemicals, assess potential spill hazards. Each laboratory worker should be familiar with general spill response procedures. Written protocols should be developed when extremely hazardous or large quantities of chemicals are used. Have readily available all necessary personal protective equipment and spill cleanup materials. See Chapter 6 for more detailed information.

Unattended experiments: If operations involving hazardous substances are carried out with no one present, it is the responsibility of the worker to design procedures to prevent the release of hazardous substances in the event of interruptions in utility services such as electricity, cooling water, and inert gas. Lights should be left on, and signs should be posted identifying the nature of the operation and the hazardous substances in use. If appropriate, arrangements should be made for other workers to periodically inspect the operation.

Similarly, if unattended experiments require the use of running water, the worker should develop procedures to make sure the experiment is checked periodically for water leaking from the system. Unattended experiments involving the use of running water have caused flooding damage at University of Illinois at Urbana-Champaign.

Working alone: When working with hazardous materials, it is advisable to have a second person present, or at a minimum, maintain contact via telephone.

3.2 Pollution Prevention/Waste Minimization

Waste minimization strategies usually have the dual benefits of improving safety and reducing chemical purchase and disposal costs.

It is recommended that each unit evaluate its procedures periodically to consider the possible usage of less hazardous or smaller quantities of chemicals. This evaluation may include the following issues:

• Is there good housekeeping where chemicals are used and stored?
• Are all containers properly labeled?
• If appropriate, is there an inventory of all chemicals in the unit?
• Do the chemicals in use present significant hazards to those working with them? (e.g. highly reactive, highly toxic, carcinogenic, and/or corrosive chemicals should be discouraged)
• If applicable, consider substitutes for all uses of mercury and chromic acid cleaning solutions

For further information, see the waste minimization Fact Sheets listed in Appendix 2. Additional technical information on ways to implement waste minimization is available from DRS at (217) 333-2755 or via e-mail.

3.3 Personal Protective Equipment and Personal Hygiene

Personal protective equipment and personal hygiene are basic aspects of laboratory safety. Wearing appropriate personal protective equipment and practicing good personal hygiene as described below will minimize exposures to hazardous chemicals during routine use and in the event of an accident.

Attire: Wear a lab coat or apron, cover legs (no shorts or skirts) and feet (no sandals or open-toed shoes), confine loose clothing and long hair. Nylons and/or pantyhose are not recommended because they may melt upon contact with acid.

Eye protection: It is state law and campus policy (section V/B-1.4 of the CAM) that personnel including students, staff and visitors in laboratories wear safety glasses, goggles, or face shields at all times where eye hazards are a possibility. Goggles are recommended when chemical splashes are possible.

Contact lenses may be worn in the laboratory; however, they do not provide any protection of the eyes. Persons who wear contacts must use the same eye protective equipment as persons who do not wear contacts.

Face shields: Full-face shields must be worn when conducting a procedure which may result in a violent reaction. Full-face shields with bottom caps to protect the neck are preferred because they provide the best protection.

Glass tubing: When inserting tubing into stoppers, lubricate tubing and wear leather gloves to protect hands from being cut in the event of the tubing slipping and breaking.

Gloves: Gloves are essential when working with hazardous substances. The proper gloves will prevent skin absorption, infection or burns. Glove materials vary in effectiveness in protecting against chemical hazards. Consult a chemical resistance chart such as the one found in Appendix 4, consult a glove manufacturer, or contact DRS (217) 333-2755 for assistance in appropriate selection.

Personal hygiene: Hands should be washed frequently throughout the day, after glove removal, before leaving the lab, after contact with any hazardous material, and before eating, drinking, smoking, or applying cosmetics.

Respiratory protection: Work in a fume hood or provide adequate ventilation when working with materials that produce hazardous vapors or fumes. If the use of a respirator is required, you must comply with University of Illinois at Urbana-Champaign Respiratory Program, which includes a medical assessment, fit testings, and instructions on proper use.

3.4 Hazard Assessments

For each task involving hazardous materials or physical hazards, a written hazard assessment must be conducted and certified. Tasks involving similar hazards may be grouped together on a single assessment form. Sample assessment and certification forms for common chemical hazards are presented in Appendix 5. Note that these sample hazard assessment forms may not cover all the chemical hazards you may encounter.

Supervisors and Principal Investigators are responsible for conducting hazard assessments. Such assessments should not be limited to chemical hazards, but should also include such issues, when applicable, as radiation hazards, biological hazards, heat and cold hazards, and physical hazards.

3.5 Handling and Storage of Chemicals

Hazards associated with various chemicals and gases vary widely. Understanding the hazards associated with a compound and minimizing the quantity used and stored in the lab will decrease chance of injury.

Compressed gasses: Use appropriate hand carts to move compressed gas cylinders. Gas cylinders should be capped and secured to a cart during transport. Highly toxic gases should not be moved through the corridors, particularly during business hours. Always consider cylinders as full and handle them with corresponding care.

Gas cylinders should be stored in well-ventilated areas with their protective caps on. Gas cylinders should be secured (e.g., strapped or chained in place) to reduce the chance of being knocked over. Do not store cylinders near heat or high traffic areas. Do not store flammables and oxidizers together. Do not store empty and full cylinders together. Storage of large quantities of cylinders should be in an approved gas cylinder storage area. Refer to the Compressed Gas Safety Fact Sheet.

Containers: Make sure all containers are of good integrity. If deteriorated containers are found, dispose of the chemical or transfer it to a new container. Make sure that the container is appropriate for the chemical stored; for example, hydrofluoric acid must not be stored in glass and some oxidizers should not be stored in plastic containers. Waste halogenated solvents may not be stored in metal safety cans due to the potential for corrosion. Flammable materials, if removed from their original containers, should be stored in appropriate containers, such as safety cans or other Department of Transportation (DOT) approved containers. If in a substantial amount (>4 liters, but less than 20), waste solvents should be stored in poly jerricans (Central Stores stock number 37-38-1800 for the 10 liter size).

Cryogenic liquids: These items present the potential hazards of fire or explosion, pressure buildup, embrittlement of structural materials, frostbite, and asphyxiation. Work areas must be well ventilated. Cryogenic liquids must be stored, shipped, and handled in containers that are designed specifically for this purpose. Because of the extreme cold and splash hazards, skin protection and eye protection - preferably a face shield - should be worn when handling cryogenic liquids. First time users of cryogenic liquids should have direct supervision and instruction from an experienced user when attempting transfers from one container to another.

Handling: Encourage the use of poly coated bottles or use bottle carriers for transporting chemicals which are in glass containers. Close caps securely. Pour chemicals carefully. Never add water to concentrated acid; rather prepare dilute solutions by adding acid to water. Containers holding more than five gallons should be grounded when transferring flammable liquids.

Labels: Make sure all labels are legible. Label all containers with the chemical name and appropriate health hazard warning(s). A chemical is considered to pose a health hazard if it is in one or more of the following classes: carcinogen, corrosive, irritant, sensitizer, toxic, or highly toxic. Information on whether a chemical poses a health hazard may be found on the Material Safety Data Sheet.

Date all peroxidizable and other chemicals which may become unstable over time; test and/or dispose of them when appropriate. Common examples of chemicals that form peroxides upon aging are: ethyl ether, isopropyl ether, tetrahydrofuran, and dioxane. See Appendix 6 for a more complete listing of chemicals that can form peroxides upon aging.

Storage: Avoid storing chemical containers in hard to reach areas. Chemicals should be segregated by hazard classification. Once segregated by hazard class, chemicals may be stored alphabetically. Basic segregations should keep:

• oxidizers away from organics
• air/water reactives away from air and water
• caustics away from acids
• cyanides, sulfides away from acids

Laboratories with large numbers of hazard classifications may choose to further segregate chemicals.

Volatile chemicals should be stored in volatile storage cabinets, or temporarily in fume hoods when cabinets are unavailable. If volatile substances are stored in a hood, other uses of the hood should be restricted to activities compatible with the chemical and physical properties of the stored or used chemicals. When volatiles must be stored in a cooled atmosphere, flammable material refrigerators, explosion-proof refrigerators or cold rooms designed for this purpose must be used. Refer to the Facilities & Services Flammable Storage Cabinets webpage.

3.6 Fume hoods and other engineering controls

All users of fume hoods at the University of Illinois at Urbana-Champaign (University of Illinois at Urbana-Champaign) campus should comply with the Division of Research Safety (DRS) Work Practices for Chemical Fume Hoods. Fume hoods and other engineering controls, such as vented gas cabinets, should be surveyed annually by a qualified person (from DRS, O & M, or an outside contractor) with a written report of the results maintained by the unit in charge of the laboratory.

Fume hood velocities for all hoods on campus are currently evaluated on an annual basis by DRS at no charge to the users. The face velocity of the hoods should fall between 80 and 120 feet per minute (fpm) with the sash positioned at approximately half open, unless specified otherwise. (In general, fume hoods should not be used with the sash fully open.) If the face velocity is between 80 and 120 fpm on the day of the evaluation, the fume hood will bear a green sticker on the fume hood cabinet with an arrow pointing to the appropriate sash position. If the face velocity is between 60 and 79 fpm or above 120 fpm, the hood will have a yellow sticker with an arrow indicating sash position. This indicates that the hood is "Restricted" and should not be used for protection from highly toxic substances. Finally, if the face velocity of the fume hood is below 60 fpm, the hood will display a 5" x 7" DANGER sign, which states that the fume hood should be used for storage only.

Users should be certain that their fume hood has a sticker on it and that the date on the sticker is less than a year old. If the sticker is not green, indicating that the fume hood was not functioning properly when last tested, users should work with their departmental business manager to have the fume hood repaired. For maintenance of fume hoods, users should contact the (PC&M) Service Office at 3-0340. (In most cases, academic units are financially responsible for the maintenance of fume hoods.)

Because the status of the fume hood can change within one year, continuous air flow indicators are recommended. New fume hoods should be equipped with air flow monitoring devices which will alert the user if there is a problem with air flow. For older hoods without air flow monitoring devices, a simple visible test to ensure flow into fume hoods and other ventilating devices is to tape a tissue to the hood and note its movement when the exhaust fan is turned on.

Protective equipment other than fume hoods should be checked periodically by the laboratory supervisor to ensure that the equipment is functioning properly. DRS will assist upon request. Any questions or requests for assistance in evaluation of fume hoods and other engineering controls may be directed to DRS at (217) 333-2755 or the PC & M Service Office (217) 333-0340.

3.7 Prior approval for use of certain hazardous materials

The responsibility for approval of the acquisition and use of toxic chemical agents rests with the laboratory supervisor. Certain materials including radioactive materials, recombinant DNA and certain biohazardous materials require prior internal (campus) or external approval. Wastes of hazardous materials with multiple hazards (chemical, radioactive and/or biohazardous) often complicate disposal. The Division of Research Safety (DRS) cannot guarantee that there are outlets for wastes exhibiting multiple hazards and we therefore recommend that you contact us prior to conducting experiments that might generate such wastes. Questions concerning the need for approval should be directed to DRS (217) 333-2755.

3.8 Special provisions for select carcinogens, reproductive toxins and acutely toxic chemicals

In addition to the general safety guidelines mentioned above, special precautions are needed when handling particularly toxic chemicals - such as select carcinogens, reproductive toxins, and chemicals with a high degree of acute toxicity. The laboratory supervisor should ensure that these and other precautions designed to minimize risk of exposure to these substances are taken. The following are minimum guidelines:

• Quantities of these chemicals used and stored in the laboratory should be minimized, as should their concentrations in solution or mixtures. Work with carcinogens, reproductive toxins and acutely toxic chemicals should be performed within a functioning fume hood, ventilated glove box, sealed system, or other system designed to minimize exposure to these substances. (The exhaust air from the ventilation systems may require scrubbing before being released into the atmosphere.) In all cases, work with these types of chemicals should be done in such a manner that the Occupational Safety and Health Administration's (OSHA) permissible exposure limits or similar standards are not exceeded.
• Compressed gas cylinders that contain acutely toxic chemicals, such as arsine and nitrogen dioxide, should be kept in ventilated gas cabinets.
• The ventilation efficiency of the designated fume hood, glove box, or gas cabinet, and the operational effectiveness of mechanical and electrical equipment used to contain or manipulate these special substances should be evaluated periodically by the laboratory personnel at intervals determined by the laboratory supervisor. The interval of evaluating systems may vary from weekly to biannually depending upon the frequency of usage, quantities employed and level of hazard.
• Each laboratory utilizing these substances must designate an area for this purpose and sign or mark this area with an appropriate hazard warning. The designated area may be an entire laboratory, an area of the laboratory, or a device such as a fume hood or glove box. The designated area should be marked with a sign stating "DANGER, specific agent, AUTHORIZED PERSONNEL ONLY" or comparable warning sign.
• All laboratory workers who work in a laboratory which has an area designated for use with carcinogens, reproductive toxins and/or acutely toxic chemicals must be trained about the deleterious effects of these substances plus signs and symptoms regarding exposure to these substances. This training is required even for those who do not actually work with the substances. Training to ensure the safe handling and storage of these substances is required for those who use these materials. This training is the responsibility of the laboratory supervisor and must be done prior to the use of any of these materials.
• Laboratory workers using these chemicals must have access to appropriate personal protective equipment (available at no expense to the workers) and must be trained on how to properly utilize this equipment.
• Detection equipment may be required in laboratories where highly toxic chemicals (especially poisonous gases) are used.
• All wastes contaminated with these substances should be collected and disposed of promptly as outlined in the University of Illinois at Urbana-Champaign Chemical Waste Management Guide. For disposal assistance, call the DRS Chemical Safety Section (217) 333-2755 contact via email. Treatment of waste products to lessen or eliminate their toxicity as part of the experimental protocol is encouraged as a way of minimizing health hazards and the amount of waste, only if such treatment can be performed safely.
• The designated working area shall be thoroughly decontaminated and cleaned at regular intervals determined by the laboratory supervisor. The interval may be as short as one day or as long as six months depending upon the frequency of usage and level of hazard.
• Special precautions to avoid release and exposure to carcinogens, highly toxic chemicals and reproductive toxins must be utilized. For instance, volatile substances should be kept cool and contained. Gas cylinders should have properly functioning valves, check valves, regulators, containment which can withstand pressure buildup, and appropriate piping; and dispersive solids should be kept in closed containers, used in places with minimal air currents, and appropriate contact materials should be used to avoid static charging.
• Emergency response planning for releases or spills should be prepared by the laboratory supervisor and included in the training of the laboratory workers and others who may be affected in the building. DRS and the appropriate Fire Department should be involved in this planning.