Appendix C - Process Hazards Identification Checklist

The following questions and guidelines are to be used in designing experiments that will minimize potential hazards associates with the type of chemicals addressed below.  
A.  Determination of Chemical Hazard

1. Determine, based on SDS information, if the chemicals used or the reaction byproducts can be classified as one of the following: 
2. carcinogen
3. allergen
4. reproductive hazard (mutagen, teratogen)
5. acutely toxic
6. peroxide formers

If the answer is "yes", notify the CHO (ext. 4420).

1. Are any of the process chemicals or reaction byproducts an OSHA regulated substance? See Appendix D. If "yes", contact the Chemical Hygiene Officer.
2. Will perchloric acid be used in the process? If "yes," contact the Chemical Hygiene Officer.
3. Has the use of less toxic materials been considered and is the quantity reduced to the smallest amount necessary for the experiment?
4. Is the ventilation/containment system adequate to control the materials being used and generated?  There should be a minimum of 100 linear feet per minute.

B.  Hazards Assessment of Chemical Process

1. Has the literature for the intended process been researched to identify the accidents that have occurred and their causes/prevention?
2. Will an exothermic reaction occur if any of the following failure modes occur?
3. quench failure or loss of external cooling
4. change in purity of material or catalysts
5. excess or deficiency of one reactant
6. loss of agitation
7. local hot spot due to inadequate mixing
8. excessive point or surface temperature leading to  "runaway" reactions
9. delayed onset of batch reaction while continuing reactant addition
10. leakage of coolant into reactants
11. backflow of a reactant due to depressurizing system
12. excessive heat
13. high-pressure reaction acceleration
14. For experiments being scaled up or down, have the following been evaluated for impact on reaction rates?
15. change in surface area, heat and cooling capacity
16. degree of agitation and mixing
17. changes in reactant proportions
18. rates of addition
19. Are the reactants being used endothermic compounds with low energy activation values?
20. Are amine metal oxysalts used in a process that is subject to friction, heating or impact?
21. Are pyrophoric materials used in a process that will result in oxidation or hydrolysis?
22. Are water reactive compounds used in a process that could result in contact with water?
23. Has the oxygen balance of the compounds been evaluated to determine explosive potential?
24. Are peroxidizable compounds used or produced which are concentrated due to heating or evaporation?
25. Has the creation of toxic off gas byproducts due to contact between reaction byproducts and reactants or process surfaces been evaluated?
26. Will flammable liquids be used such that the ignition temperature for the vapors produced can be exceeded?
27. Are the reactants or reacting byproducts highly corrosive?
28. Is spontaneous polymerization possible for the reaction process?
29. Is the wrapping material on the dewar flask compatible with the process chemical?

C.  Hazards Assessment Physical Process

1. 1. Are precautions implemented to prevent implosions or explosions of flasks?
   2. Are pressure relief valves/devices available for sealed system under cryogenic cooling?
   3. Are safety relief devices provided for pressurized processes?
   4. Are the safety relief devices capable of operating at the pressure of concern?
   5. Are the process flow lines, containers and clamps capable of withstanding process pressures?
   6. Are pressure relief devices located so that personnel will not be exposed if these devices are activated?
   7. For laboratory projects involving a continuous flow of water (such as condensers), is protection provided to prevent flooding from tube failures, pump failures, blockage in flow lines, connection disruptions and pressure spikes?
   8. Are proper regulators and valve fittings used for compressed gases, especially CO2 and corrosive gases?
   9. Is the glass and plastic equipment used for pressurized or vacuum processes adequate?
   10. Are pumps adequately protected from the process reactants and byproducts with traps?
   11. Are guards provided for belt driven mechanical pumps?

D.  Hazards Assessment Fire and Electrical Process

1. Are ground fault circuit interrupters provided in areas where there is a danger of splashing water into the receptacle?
2. Is equipment layout such that flammable materials are segregated from ignition sources?
3. Where electrical equipment is used with flammable liquids are measures in place to prevent heating above the ignition temperature of the liquid?
4. Is bonding and grounding protection provided for containers, especially large metal drums of flammable liquids?
5. Are variable autotransformers (heaters, stirrers) located so as to prevent contact between the windings and flammable vapors?
6. Are heating mantles properly grounded?
7. Is heating equipment provided with automatic temperature controls and with high temperature limit switches?
8. Are non-sparking tools and motors used for work involving flammable chemicals?
9. Is electrical equipment positioned to guard against liquids being spilled onto the equipment?
10. Are drying ovens constructed so that temperature controls and heating elements are separated from their interior atmosphere?
11. Are highly flammable solvents such as ethers stored in explosion proof refrigerators?
12. For work involving the generation of flammable vapors, are all the laboratory switches explosion proof?
13. For stirring and mixing devices, can these devices be remotely shut off?  (e.g. electrical shut off for laboratory)
14. Do all hot plates have their heating elements completely enclosed?
15. Are peroxide-forming chemicals labeled with "received" and "opened" dates?
16. Are the chemical and physical properties of the reagents and reaction products known and understood?
17. Are the medical emergency measures for the respective chemicals covered in the SDS and readily available?
18. Is/are the reaction(s) understood and predictable under normal circumstances as well as the factors that can cause upset conditions?

E.  Hazardous Waste Planning

1. Have provisions for hazardous waste disposal been addressed?
2. Are provisions provided in the experiments to prevent the release of hazardous materials into the drain system?
3. For solvent distillations, are trapping devices adequate to prevent entrainment of solvent vapors into stream that is released to the drain?
4. Have steps been taken to minimize the amount of waste generated by the process?
5. Are methods included in the process to render the reactants and by-products non-hazardous?
6. Are bimetallic thermometers used in place of mercury thermometers to prevent generating mercury contaminated waste?
7. See Appendix F - Hazardous Waste… Handling and Disposal.

F.  Administrative Preparation Assessment

1. Is a detailed and updated written protocol available to all personnel performing part or all of an assigned experiment or research project?
2. For experiments that will run continuously, are provisions made for periodically checking the experimental set-up to ensure operational safety?
3. Is there a written protocol provided with instructions for handling upsets and credible emergencies?
4. Is there a schedule for providing routine maintenance and checks made of interlocks relied on to shut down equipment?
5. Has training in protocol been provided to all personnel performing the laboratory experiments or research projects?
6. Are suitable materials available for neutralizing and containing materials that could be spilled during the process?
7. What process hazards are introduced by reaction products and/or byproducts?
8. Are special detectors and alarm devices needed to warn of the generation of hazardous materials?
9. If special detectors and alarm devices are needed, are protocols and equipment available for periodic calibration and testing of these devices?
10. If special detectors and alarm devices are used, has the Chemical Hygiene Officer and Campus Security been notified of what they indicate and how to respond?
11. For operations involving liquid nitrogen as a coolant, have precautions been instituted to eliminate the condensation of liquid oxygen before charging a trap?