SOP On Safety In Quality Control Laboratory

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SOP On Safety In Quality Control Laboratory

  • OBJECTIVE:

The purpose of this SOP is to lay down a procedure for describe safety aspects and precautions during working in the department.

  • SCOPE:

This SOP on Safety in Quality Control Laboratory is applicable for guidelines regarding safety hazards occurring during laboratory working and to guide on safe handling of various reactions during analysis, and handling some of corrosive and poisons like Potassium Bromide in Quality Control Department at manufacturing site.

  • RESPONSIBILITY:
    • Analyst or his designee shall be responsible for follow the SOP.
    • The Head of Quality Control Department or his designee shall be responsible and implementation of the SOP.

PROCEDURE:

  • BASIC SAFETY PRACTICES – SOP on Safety in Quality Control Laboratory
  • Keep the work area clean before and after each activity/analysis.                    
  • Deposit garbage, wastes etc. in the appropriate dustbins meant for them. Keep the floors dry by mopping up any spillage soon after it occurs.
  • Keep all gangways, emergency exits and staircases free from obstructions. Make sure that all fire-fighting equipment is readily accessible.
  • Collect broken glass pieces with a broom and dustpan. Broken pieces of glass must be picked up from the floor by using a wet cloth and ‘never with bare hands’. All broken glassware should be collected in a separate dustbin. At the end of the week or as and when required, all broken glassware should be disposed in the scrap yard.
  • Do not eat, drink or smoke in the laboratory.  Do not store food in the work areas and do not keep food or drinking water in refrigerators that are used to store chemicals, reagents and biological materials. Do not drink water kept in laboratory wash bottles.
  • Wash the hands thoroughly with soap and water or where necessary with cleaning agents, after leaving the work area.
  • Wear suitable protective gear such as helmets, safety goggles, face shield, safety foot wear, gloves (acid proof, alkali proof and Kevlar) etc., while doing hazardous jobs and during sampling in the Stores area.
  • Always use a rubber bulb or pump to withdraw solutions. Use a dispenser to withdraw corrosive liquids like strong acids or alkalis.
  • When boiling a solution in a test tube keep the mouth of the test tube away from the co-worker next to you and away from yourself.
  • Handle hot glassware carefully e.g. distillation assembly, articles removed from muffle furnace, driers etc.  (Hot glass looks exactly the same as cold glass). Always wear Kevlar hand gloves while handling hot glassware.
  • Never carry out unauthorized experiments and never taste, smell or inhale any chemicals in the laboratory.
  • An open flame may be ignited only when no flammable solvents are in the vicinity.

  • BENCH OPERATIONS – SOP on Safety in Quality Control Laboratory
    • Do not start an experiment on a bench already crowded with apparatus or equipment. Clear the workbench of unwanted chemicals and reagents.
    • Before starting a test, familiarize yourself with the known hazards of the material (Refer Material Safety Data Sheet) and the operations to be performed and equip yourself with the necessary protective gear and devices.
    • Ensure that all reagent bottles, containers and other glassware in use are correctly and clearly labeled.
    • Pour liquids in a direction away from the label to avoid damaging the label. If any liquid spills over the sides of the container, wash or wipe the surface with water before returning it to the shelf.
    • Examine all glassware for damage before use. Do not use cracked, chipped or any other defective glassware.
    • Support all large glass flasks adequately. Additional support at the base improves stability.
    • Use lubricant and a cloth for protection when inserting glass tubing rods and thermometers into bungs or tubing. While cutting a glass tube or rod, use gloves and safety goggles.
    • To remove tight glass stoppers, tap alternately on each side of the stopper or sonicate. If this does not work and the contents of the bottle are not flammable or toxic, gently warm the neck of the bottle.
    • Carry out tests involving hazardous and fume-generating chemicals only in a fume hood with   proper exhaust systems.

  • SOLVENT EXTRACTION – SOP on Safety in Quality Control Laboratory
  • When using a separating funnel for solutions containing solvents release the pressure developed on shaking by inverting the funnel with the stopper securely held and opening the tap with care.  Point the funnel away from the eyes and any source of heat such as a naked flame or heating mantle.Ensure that the condensing system above a Sox let extraction unit is adequate to cope with the solvent in use.Removal of solvents in an experiment involving flammable solvents should be carried out using a water-bath or electrically heated bath.For low-boiling liquids such as liquor ammonia, ether etc., cool the container before opening, using protective equipment such as gloves and safety goggles.
  • HANDLING OF GAS CYLINDERS       
  • Store cylinders in a well-ventilated place in an area where no flammable substances are stored.
  • Protect cylinders from direct sunrays and avoid storage on wet ground.
  • Never drag or roll a compressed gas cylinder. Use a handcart to transport cylinders.
  • Use cylinders in an upright position. Always secure and chain them to prevent accidental knocking over.
  • Always use a pressure-reducing regulator free from oil and grease, attached to the cylinder valve.  Keep the metal cap in place to protect the cylinder valve.  Before removing a regulator from the valve, close the valve and release the gas from the regulator.
  • Do not use an oxygen cylinder with oily hands or oily gloves as even a small amount of oil or grease may ignite violently in the presence of oxygen released under pressure.
    • HAZARDOUS CHEMICALS
  • Wear safety goggles, and nose masks where considered necessary. Use a face shield and protective gloves while handling hazardous chemicals.
  • Transport containers of capacity of one liter or more in stainless steel carriers and containers of capacity five liters or more on a trolley and do not carry the chemicals in open containers.
    • FLAMMABLE LIQUIDS
  • Store bare minimum stock of solvents in the laboratory. Store liquids that are not in use preferably in a suitable fire resistant cupboard or bin, made of steel or wood. The cupboard must be robust, properly labeled and not used for any other materials.          
  • Return the solvent bottles to the storage area after use.
  • Do not store flammable solvents in the refrigerator as the electrical control and switches in the refrigerator may cause sparks, which could be a source of ignition for flammable vapors. Do not store flammable liquids near oxidizing agents such as chromic acid, permanganates, chlorate and per chlorates.
  • Isolate experiments which require large amounts of flammable solvents and ensure that adequate fire-extinguishers are available. Use a water-bath or electric heating mantle when large amounts of flammable solvents are to be heated. Do not pour out solvents near a naked flame.
  • If any spillage of flammable solvents occurs, use a suitable absorbent to absorb the liquid and dispose off the contaminated absorbent by incineration in a pit.
  • Do not pour water-immiscible solvents down the drains.
  • Never mix miscible and immiscible waste solvents in a common bottle or carboy.
    • CORROSIVE CHEMICALS
  • While handling corrosive chemicals, use safety apparel such as nose masks, rubber gloves, safety goggles, rubber aprons etc. Avoid contact of the chemical with body surfaces, including the alimentary and respiratory system.
  • Do not store large bottles of acids and other corrosive materials above waist level.
  • Do not leave apparatus containing corrosive materials at the sink, to be washed; always drain out the contents and rinse the apparatus with tap water before leaving it for washing.
    • HANDLING OF POISONOUS CHEMICALS    
  • Handle poisonous chemicals with abundant caution.  Ensure that the containers are well sealed after use and only then placed in the cupboard.
  • Carry out the work involving poisons in the fume hood only and do not inhale poison fumes. Wear gloves if large volumes are to be handled.
  • After working with poisonous chemicals wash the work place and contaminated glassware with dilute alkali solutions followed by water.
  • Keep antidotes for each poisonous chemical (up to the extent possible) in the laboratory.
  • Wash any contacted skin area with soap and water at once.
    • ELECTRICAL HAZARDS
  • See that all wires are properly insulated and instruments well earth.
  • Ensure that no water points or rubber connections carrying water are allowed to leak on to electrical plugs and switches.
  • Ensure that worn or damaged cables, sockets and plugs are replaced promptly.
    • BACTERIAL HAZARDS
  • Place contaminated glassware in a chemical disinfectant immediately after use and before cleaning and reusing.
  • Decontaminated waste, including specimens of bacteria, by effective means prior to disposal as refuse or seal in sturdy, impervious containers for incineration.
  • Sterilize culture plates and tubes adequately before washing or discarding them.
  • Clean bench tops, incubators, furniture and floors that may be contaminated, at least weekly with an effective disinfectant.
  • Clean and disinfect any spillage immediately.
    • FIRE SAFETY
  • Ensure proper use, storage and disposal of flammable and combustible liquids/ solids used in the laboratory.
  • Equipment and instruments to be inspected periodically for electrical wiring, earthing and general cleanliness.
  • Check regularly all fire-fighting equipment and ensure that they are in operating condition.  Ensure that a sufficient number of people are trained in the use of the equipment.
  • If any fire is small immediately control it with a fire extinguisher. If it is of a more serious nature, raise the alarm and follow the factory drill for fighting fires.
  • Use carbon dioxide or any other suitable fire extinguishers for instruments.
  • Identify the safety squad and train them.
    • EMERGENCIES
  • In case of an emergency know the location and operation of

            i.    Fire extinguishers

            ii.   Safety air shower, Eye washer

            iii.  Fire alarm

  1. Telephones
  2. Ensure that there is a first-aid kit in the laboratory and that it is adequately stocked with the basic supplies of first- aid materials.
  3. In an emergency follow the laid down factory procedure and have first aid rendered by people trained in first-aid techniques.
  4. Keep the emergency exit free of obstructions.
  5. Do not use lift for evacuation during an emergency. Use the staircase.
    1. ACCIDENTS
  6. Treat minor injuries by rendering first aid and then send the victim to a medical center for further treatment.
  7. For major injuries arrange for immediate medical aid.  Do not move the person except to a position of less danger. Keep the person warm and quiet to minimize the effects of shock.
  8. In the event of poisoning immediately give large amounts of water to dilute the poison and call for a doctor.  In the case of gas poisoning transfer the victim into fresh air surroundings immediately and if breathing has stopped give artificial respiration. If person is unconscious, do not give anything from mouth.
  9. In case of electric shocks switch off the main switch and push the victim away from the electric wires with a dry non-conducting material, by standing on a dry board or a rubber mat. Do not touch the victim until contact with the source of current is broken.
  10. Treat eye injuries by flushing with water immediately for about 15 minutes and rush the victim to a doctor for treatment.
  • TRAINING:

Trainer             : Head – Quality Control

Trainees           : Quality Control chemist / Sectional Heads

  • DISTRIBUTION:

As per SOP Format SOP

  • ANNEXURE:

Nil

  • REFERENCES(S) :

Nil

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