Welcome to the Materials Science

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Welcome to the Materials Science Engineering
Dept. Semi-Annual Safety Seminar

• Presented By
• Dr. Richard Knight
• Department Chemical Hygiene Officer (CHO)
• E-mail knightr_at_coe.drexel.edu
• Tel. [phone]

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Important Phone Numbers

• Fire 9-911
• Police 9-911
• Ambulance 9-911
• Drexel Public Safety [phone]
• Chemical Spill gt500 ml Call Public Safety (215)
  895-2222
• Chemical Spill lt500 ml Call Ext. 1844 and (215)
  895-5891 or [phone]
• Chemical Safety [phone]
• MSE Department CHO Ext. 1844
• Drexel Facilities Mgt. Ext. 2808

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Important Names Numbers
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Why we do this1

• My desks tidy hows yours?

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Why we do this2

• Whats wrong with this picture?
• Now we wouldnt do anything like this now would
  we?

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Why we do this3

• Tripping the Light Fantastic?

• Lets do lunch! Mmm!

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How are we doing?

• Recurring Issues
• Secondary labeling of chemicals/samples.
• Incompatible storage of chemicals.
• Evidence of food/drink in labs.
• Irregular updating of chemical inventories and
  MSDS folders.
• Full Chemicals to be Disposed Of containers.

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General Topics of Discussion

• Awareness
• Emergencies
• Attire
• Eye Protection
• Personal Protective Equipment (PPE)
• Cleanliness

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General Topics (Cont.)

• Chemical Safety
• Hazard Classifications
• Chemical Inventory
• Chemical LabelingNFPA
• Chemical Storage
• Chemical Handling
• Chemical Waste
• MSDS Sheets
• Chemical Spills
• Glassware

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Awareness

• Be aware of your surroundings and of the possible
  dangers involved, not only in what you are doing,
  but also what others around you are doing.
• Know your escape routes in case of emergencylook
  for alternate ways out.
• Be familiar with the locations of Fire
  Extinguishers, Fire Alarms, Telephones, etc.

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Emergencies

• Determine the type of emergencye.g. fire,
  chemical spill, an accident involving injury,
  sudden illness, electric shock etc.
• Call Drexel Public Safety, Ext. 2222.
• If life-threatening or not sure, call 9-911.
• STAY CALMDO NOT PANIC!

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Attire (Clothing)

• Shoes No open-toed shoes or sandals in the labs
  at any time. Avoid shorts when working with
  chemicals, hot metal etc.
• Lab Coats Should be worn in the lab. if you are
  working with chemicals of any kind.
• Long Hair Should be tied up if working with
  rotating machinery.

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Eye Protection

• Safety Glasses are to be worn at all times while
  in the laboratoryexcept in designated Office
  areas.
• You will be issued a pair of approved safety
  glasses by the lab you are working inlook after
  themyou will be responsible for turning them
  back in when you leave.

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Other Personal Protective Equipment (PPE)

• Hearing Protection Ear plugs, ear muffs, if
  usedmust be OSHA approved.
• Respirators
• Various typesdust masks to full face with
  hazard-specific filter cartridges.
• You must be enrolled into the Universitys
  Respirator Protection Program - dont just buy
  and use it! Prior to use one must have a
  pulmonary lung exam and a fit test.
• Unsuitable for users with beards.

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Cleanliness

• Laboratories must be kept clean and tidy at all
  times.
• There is no reason to have a laboratory in a
  constant state of disarray
• Safety Health conducts quarterly inspections.
• The Dept. also conducts periodic walk-throughs
  verbal warnings, written warnings and fines will
  be issued for violations, especially repeat
  violations!

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Chemical Safety

• Hazard Classifications
• Chemical Inventory
• Chemical Labeling
• Chemical Storage
• Chemical Handling
• Chemical Waste
• MSDS Sheets
• Chemical Spills

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Hazard Classification

• Stable Chemical or Non-Hazardous Chemical, e.g.
  Sodium Chloride (NaCl).
• Flammables
• Poisons
• Carcinogens
• Reactive/Explosive
• Oxidizers
• Corrosives
• Acids
• Bases
• Toxic
• Biohazards

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Chemical Inventory

• A chemical inventory must be maintained for every
  laboratory in the Department.
• The chemical inventory must be in a binder that
  is clearly labeled, easily located and readily
  available for anyone to review.
• The inventory binder MUST list all chemicals in
  the lab., along with their location, amounts on
  hand, storage container and hazard
  classification.
• The inventory must be updated monthly.
• A copy of the chemical inventory must be sent to
  the University Department of Safety and Health
  annually.

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Chemical InventoryExample

• Location Drexel University, Bossone Building,
  Room 110D (Electron Microscopy Lab.)
• Contact Dr. MicroScopE
• Tel. (215) 895-XXXX
• E-mail MicroScopE_at_drexel.edu

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Typical Inventory Sheet
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Chemical Labeling

• The Department has developed a label template
  (downloadable from the web http//www.mse.drexel.e
  du/Facilities/lab_safety.asp) to be used for all
  chemicals currently in use in the
  departmentplease remember to use it!
• There is no excuse for having a chemical in this
  Department incorrectly labeled.

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Correct Chemical/Solution Labeling

• Hydrochloric Acid 25 ml
• Nitric Acid 35 ml
• Sodium Hydroxide 22 g
• Contact ltNamegt Ext. 2334
• E-mail MicroScopE_at_drexel.edu
• Date 7/11/05

Use the Label Template for labeling all
samples, chemicals in beakers, etc.
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National Fire Protection Agency (NFPA)

• NFPA labels must also be used on every
  chemical-containing container in this Department.
• The NFPA label assists in extinguishing of fires
  and/or other accidents that could put someone,
  maybe you, at risk.

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All Chemicals MUST have an NFPA sticker attached
to them!
NFPA Labels

• BLUE Health Hazard
• RED Fire Hazard
• Yellow Reactivity
• White Specific
• This information is on the MSDS Sheet.

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Chemical Storage

• Chemicals must be stored according to their
  hazard class. This information can be obtained
  from the MSDS.
• NEVER store chemicals in a fashion that would mix
  hazard classes, e.g. oxidizing acids with organic
  solvents
• Contact the University Department of Safety and
  Health for any questions concerning storage.

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Chemical Waste

• Chemical waste will be picked up by the
  University on an as-needed basis.
• The containers to use for chemical disposal are
  the large one-gallon glass containers.
• Do not label these containers as chemical
  waste. Only Drexel Safety Health Dept. can
  place such a label on that container. Label your
  containers as Chemicals to be Disposed Of or
  Hazardous Material.
• Do not place the date on the hazardous material
  container. The University Safety and Health Dept.
  will place the date on the container during the
  chemical pickup.
• A complete list of all chemicals known to be in
  the container should be written (in words) on the
  container label.
• When a container is full you legally have 72
  hours to fill out a chemical waste removal form
  and either Fax it to Safety and Health, or fill
  it out on-line.

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Materials Safety Data Sheets

• MSDS sheets are written in sections to assist you
  in your efforts to determine safe handling,
  storage, usage and disposal of any chemical you
  may encounter.
• These also provide you with the First Aid
  measures for the stated chemical.

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Materials Safety Data Sheet (MSDS) Websites

• http//www.fishersci.com
• http//www.vwr.com
• http/www.hazard.com
• Plus any vendor you order from must be able to
  provide an MSDS for your product on request.

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MSDS Binder

• An MSDS book/binder MUST be located in a readily
  visible and accessible place inside each
  laboratory.
• This book MUST contain the MSDS sheets for every
  chemical in the laboratory, arranged in
  alphabetical order.

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Chemical Spills

• In the event of a chemical spill
• Identify the chemical. Reference acutely
  hazardous list.
• Determine severity of spill lt or gt 500 ml?
• If lt500 ml and not acutely hazardous --gt use the
  Chemical Spill Kit provided in the laboratory.
• If gt500 ml or acutely hazardous
• Notify all personnel in area.
• Shut down all experiments, instruments and
  equipment.
• Evacuate the area and close the door.
• If contaminated with hazardous materials
  immediately implement personal decontamination
  procedures.
• Contact Public Safety [phone]. Provide
  Public Safety with essential information
  pertaining to the spill.
• Wait for instructions from either Public Safety
  or the University Department of Safety and
  Health.
• Reference the Hazardous Material Emergency Spill
  Response Policy for detailed response actions.

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Glassware

• 3 Types
• Clear, Brown and Lab. Glass.
• All glass must be disposed of in accordance with
  the University glass waste disposal policy.
• http//www.materials.drexel.edu/glass.htm
• DO NOT USE THE GLASS WASTE CONTAINERS AS TRASH
  CANS!

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Glass Storage/Cleanliness

• Clean glass storage may be anywhere in the lab.,
  provided that it is not above eye level for the
  shortest person working in the laboratory.
• Keep all glassware clean and free of chemical
  residues.

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Other Safety Considerations

• Gas Cylinders.
• Other Hazards
• Noise (N)
• Mechanical (M)
• Thermal (T)
• Electrical (E)
• Particulates (P)
• Chemical (C)
• Radiative (R)
• Explosive (X)

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Gas Cylinders/Regulators

• Labs use Air, Fuels (CH4, C3H6, C3H8, C2H2, H2),
  O2, Inert Gases (Ar, He), N2 and specialty gases,
  e.g. Cl2.
• High Pressure Gases
• Potentially very dangerouspressures of 100-2,500
  psi.
• Acetylene
• Unstable/explosive gt60 psi. Max use pressure 15
  psi.
• Keep acetylene cylinders upright to prevent
  acetone attacking regulator seals.
• Propane/Propylene liquids (80-150 psi).
• Safety
• Move cylinders properlyuse approved
  cart/trolley.
• Ensure transport cap is in place when moving
• Secure cylinders using chains or approved clamps
  when in place.
• Regulators --gt look away when opening/adjusting.
• Only use compatible regulators.
• Avoid corroded/damaged tanks regulators.
• Use flame arrestors on all fuel manifolds/lines.

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Sources of Hazards

• Arcs/Flames N, R, T, P, C
• Robotics/Manipulators N, M
• Cyrogenics T, C, X
• Power Supplies N, E
• Powders P, C, X
• Solvents T, C, X
• Gas Cylinders C, X
• Chambers/Spray Booths T, M, X
• Reactants C, X
• Powder Handling M, X
• Spray Torches T, E, R, X

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Arcs Flames

• Noise Electric arc105 dB(A) Ar/H2 plasma
  jet127 dB(A) HVOF flame127-130
  dB(A) Flame/Rod 125 dB(A)
• Thermal 5,500-30,000 F Flames50-500,000
  BTU Plasma20-100,000 BTU (10-200 kW)
• Radiative UV, Visible, IR
• Particulate Dust gt 0.5 µm Fume lt 0.5 µm
• Chemical Ozone (O3) NOx (NO, NO2, N2O)

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Personal Protection

• Sight
• Shaded Lenses
• Hearing
• Ear plugs/ear muffs
• Acoustic panels/acoustic enclosures
• Inert i.e. enclosed chambers
• Skin
• Face shields
• Hoods
• Helmets
• Gloves
• Heavy, tightly-woven clothing
• Reflective clothing
• Close fitting clothing around neck, wrists and
  ankles
• Extremities.

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Noise

• High gas flows/accelerations through nozzles --gt
  noise
• Loudest HVOFgt130 dB(A) _at_ 2 m.
• Grit blast --gt 80-90 dB(A)
• Doubling apparent noise --gt 10 dB increase.
• Personal exposure limits (Recomm.) lt 15 min/day _at_
  gt115 dB(A)
• Practical Solution acoustic enclosures/barriers
  --gt lt80 dB(A) outside.
• Inside enclosure --gt use ear protection, limit
  daily exposure.
• Use approved full ear muffs for APS, HVOF, not
  ear plugs.
• Cont. exposure to gt120 dB(A) not recommended,
  limited by OSHA.
• Distance helps reduce exposure --gt 6 dB(A)
  decrease for each doubling of distance from
  source.

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Ventilation Heat Exhaust

• Thermal Spray hot (gt800 C), particulate-laden
  gas streams (100-3000 slm).
• Direct away from coating area/operators.
• Hazards inert gases (Ar, He etc.), water/steam,
  CO, CO2, NOx, uncombusted fuels --gt asphyxiation,
  combustion or explosion hazards.
• Thermal Spray Exhausts hoods/booths --gt 40-60 X
  process gas flow rates.
• OSHA 60 m/s gas velocity per 10 cm2 of spray
  booth frontal area.
• Excess Air dilution cooling before scrubbers/
  baghouses etc.
• Consult local regulations, plant/shop safety
  office, MSDS, etc.

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Particulate Materials

• Thermal spray exhaust --gt wide particle size
  dist'n comp'n.
• Fine particles (200 Å) from condensed vapors,
  esp. from low M.Pt. MetalsAl, Zn etc.
• Other particulates overspray, agglomerates,
  masking debris.
• Overspray
• Al, ZnO, carbides, metals (Ni, Cr, Co, Fe).
• May be toxic or carcinogenic.
• Major concern
• Fine (0.5 - 150 µm) dust particles.
• Sub-micron --gt fume --gt airborne, ingested,
  penetrate skin.
• Spray Booths/Ventilation trap all particulates.
• Wet Scrubbers largely ineffective for lt 5 µm --gt
  dry filters (cartridges/bags) --gt meet EPA
  regulations.
• Dry Filters maintenance (changing, cleaning
  etc.).
• Wet Filters toxic sludges.
• Disposal in accordance with State Federal
  Regulations.

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Particulate Materials Cont

• Blowers in vent. stacks --gt sized to prevent
  build-up in ducts --gt fire/explosion
• Powders w. passive oxide scale which readily
  oxidize (e.g. Al, Ti, Zr, Ta)pyrophoric --gt
  oxide heats of formation --gt can sustain
  combustion --gt explode if in suspension
• Handling Pyrophoric Powders
• Use extreme caution!
• Avoid sudden re-oxidation after passive oxides
  removed, e.g. in VPS, rapid pouring shaking.
• Can ignite in powder feed lines and other
  containers.
• Check the MSDS!
• Personal Protection
• Avoid contact, ingestion --gt respirators (paper
  disposable, full-face cartridge).

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Radiation

• All Thermal Spray Processes
• Intense visible light.
• Varying degrees of infra-red (IR) ultraviolet
  (UV) light.
• Arcs Plasmas
• Require direct filtration for eye protection.
• 9-12 welding glasses/shields ('s 6-8OK for
  Flame HVOF).
• Wire-arc plasma --gt reflected light exposure
  possible.
• Generate most UV IR.
• Sufficient UV --gt 1st degree skin burns.
• Loose fitting clothing --gt effective UV barrier.
• Plastic shielding --gt absorbs UV effectively.

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Other

• Exposure to high currents high temperatures.
• High pressure gas cylinders --gt take off like
  rockets if valve broken off.
• Gas sight gages --gt behind explosion shields.
• Prevent leaks of explosive, flammable and
  asphyxiant gases.
• Ventilate to prevent gas build-ups.
• Use combustible gas sensors in enclosed spaces.
• Never work alone!
• Follow regulations prescribed safety practices.
• A binder containing hard copies of this
  presentation, together with copies of pertinent
  Drexel and Department policies has been placed in
  each lab.

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Questions??
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EXAM TIME!