| Literature DB >> 35210527 |
Koji Fukuoka1, Masao Furusho2.
Abstract
Over the years, many accidents have occurred during chemical experiments in laboratories around the world. However, the methods of investigating and analysing accidents that have occurred at universities have not been consolidated, and the lessons learned from these accidents have not been shared. In this study, accident investigation reports of explosions in chemistry laboratories at two universities were analysed with an analysis tool based on the software/hardware/environment/liveware (SHEL) model. As a result, university accidents were classified as epidemiological models, and it became clear that the contributing factors to the accidents, which were investigated and analysed using the SHEL model, can be used as learning experiences and therefore applied for the prevention of accidents at other universities. Universities around the world need to come together to formulate research and analysis methods, rules for creating accident reports, etc. and provide a place for sharing information that will enable them to make use of the lessons learned from all kinds of accidents.Entities:
Year: 2022 PMID: 35210527 PMCID: PMC8873281 DOI: 10.1038/s41598-022-07099-2
Source DB: PubMed Journal: Sci Rep ISSN: 2045-2322 Impact factor: 4.379
Types and causes of accidents.
| Case Study 1 (Texas Tech University) | Case Study 2 (University of Hawaii) | |
|---|---|---|
| Type of accident | Explosion of chemical substances | Explosion of inflammable mixed gas |
| Cause of accident | The student used more than the prescribed usage limit of 100 mg of nickel hydrazine perchlorate (NHP); therefore, the powder exploded while the NHP was being stirred with a pestle | An electrostatic discharge occurred when a researcher used a pressure gauge, which ignited the hydrogen/oxygen gas mixture in the gas storage tank in which the explosive gas mixture was stored at high pressure, resulting in an explosion |
Local workplace factors.
| SHEL Element | Subdivision | Case Study 1 | Case Study 2 |
|---|---|---|---|
| Software | Procedure at the accident site | There was no protocol or standard operating procedure for synthesising high-energy substances, and wearing personal protective equipment was left to the individual’s discretion | There was no protocol or standard operating procedure for working with explosive gas mixtures, and there was no usual practise of wearing personal protective equipment |
| Hardware | Condition of equipment | There was no grounding or bonding. A tank for dry air was being used | |
| Environment | Environment of workplace, such as a laboratory | There was enough humidity to generate static electricity | |
| Central liveware | Psychological limits | Based on experience, it was found that a small amount of compound does not ignite or explode on impact even when it gets wet with water or hexane, and the risk of a large amount of NHP was thought to be similar | Work dealing with high-risk substances and processes were not always recognized as high risk by many researchers |
| Knowledge, skill, experience, education and training | Learning of techniques and methods associated with high-energy substances was completed with a literary review only; general laboratory safety training and education and training specific to this study were not undertaken | There was a lack of awareness that a mixture of inflammable gases and oxidant gases could ignite due to an electrostatic discharge or metal friction when an incubator or bioreactor is opened | |
| Communication | It was at the student’s discretion regarding when to consult the principal investigator for experiment or scale-up changes. There was no related governing university policy | The researcher told the principal investigator that the thesis had discussions about the need for keeping the O2 level within 4.0–6.9% and asked the principal investigator whether this factor should be considered and whether a fireproof lab coat was required, but (research institute) the principal investigator’s response was not known | |
| There were two communication tools for group meetings and research notes, but they were mainly focussed on experimental results and not used for safety purposes |
Organizational factors.
| SHEL Element | Subdivision | Case Study 1 | Case Study 2 |
|---|---|---|---|
| Peripheral liveware | Near-miss response | Two near misses occurred in the same research group three years before the accident. The first time, nitrogen was generated just before the completion of the reaction product and an explosion was heard. The second time, the students made a mistake when scaling up and set the measurement unit to 30 g. These near misses were not documented as lessons learned and were not disseminated to the entire university | A day before the accident, electrostatic sparks were observed several times in ungrounded metal equipment, e.g., a “cracked sound” within the 1-gallon pressure vessel when the same digital gauge’s on/off button was pressed; however, the cause was not investigated and analysed, thereby losing the opportunity to prevent the accident |
| Experiment discontinuation criteria | If a high-risk situation is observed in the event of a near miss, all work, including that with high-risk chemical substances and processes, must be discontinued, and all procedures must be investigated thoroughly | ||
| Operational status of the safety management system | The environmental health and safety inspector had conducted a safety audit/inspection of 118 chemical laboratories prior to the accident, but the principal investigator did not take corrective action in many of the cases | The laboratory safety inspection conducted with the environmental health and safety office’s “Laboratory Safety Inspection Checklist” was not comprehensive and was reduced to a mere formality. The use of gas storage tanks was not confirmed, and it was necessary to have a section dedicated to compressed gas | |
| The chemical hygiene plan did not include comprehensive risk assessment guidance for the laboratories | The chemical hygiene plan did not elaborate on how researchers should best handle safety regulations and practices | ||
| There was no obligation to undergo laboratory safety training that was provided online and in-person by the environmental health and safety staff. There was also video training offered for undergraduate students, but the need for hazard assessment before starting research in the laboratory was not mentioned | There was no policy or procedure to ensure that laboratory-specific safety trainings for individual laboratories are conducted regularly | ||
| There was no documented procedure and approval process for any changes to experimental plans | Some laboratories lacked or did not have standard operating procedures for handling hazardous substances, implementing hazardous work or having protective barriers or emergency procedures | ||
| University environment | The inspection was reduced to a mere formality and carried out in the absence of the principal investigator because the principal investigator considered it a violation of academic freedom | Lab safety inspection lacked cooperative aspects, such as inspecting the laboratory in the absence of the researcher | |
| The environmental health and safety office was stipulated to supervise chemical hygiene, but it was not under the authority of the vice president for research, and there was no authority to close the laboratory | Many researchers underestimated the chemical, biological and physical hazards and the need for personal protective equipment | ||
| Involvement of external organizations affecting the safety of the university | The laboratory standards of the Occupational Safety and Health Administration did not address the physical hazards | Funding agencies did not demand risk analysis of studies that used explosive substances | |
| Funding agencies did not have a policy to limit the quantity of high-energy compounds that could be synthesized and lacked guidelines for assessing the risks in the laboratory |
Figure 1Flow chart on how an accident should be investigated. Adapted from Ref.[30], International Maritime Organization.