SAFE OPERATING PROCEDURE (SOP)

Safe operating procedure (SOP) is define as a step by step description of a process when
deviation may cause a loss. This risk control document created by teams within the company
describes the safest and most efficient way to perform a task.The SOP sometimes are known
as the Safe Work Procedure (SWP). The document generally lists the associated hazards
involved in performing a task, what risk score is associated with the hazards (using a risk
matrix), what personal protective equipment is required, and the steps involved to complete
the activity without incident.

The document is split up to meet the above requirements as follows:

Step
Hazards
Inherent risk
Control measures
Residual risk

Each person involved in that task on site must ensure all sections of the SWP are followed.

Safe Work Procedures are also required for machinery and equipment that is used to perform
commercial activities. The procedures are required to be enforced within the workplace and
improved as conditions or equipment changes.

Purpose of SOP

This guideline supports WHS procedure Managing workplace health and safety risks. It
outlines a process to assist with the development of workplace-specific Safe Operating
Procedures (SOP) for plant, equipment, hazardous chemicals, work tasks and processes that
have the potential to cause harm to persons, plant, material or the environment as identified
from risk assessments. The process of developing an SOP is sometimes called a Job Safety
Analysis (JSA).

Guidance of SOP
SOPs may need to be developed as a risk control measure:

If indicated from the outcomes of risk assessments carried out in accordance with the
procedure for managing workplace health and safety risks when introducing new
work practices, when introducing new technology from a workplace inspection
following incident investigation which recommends a need for SOP development.

SOPs should be written with sufficient detail to ensure that someone with limited
experience or knowledge of the procedure, but with a basic understanding, can
successfully carry out the procedure in a safe manner when unsupervised. They
should be written in a concise, logical, step-by-step, easy-to-read format.

Reference to the manufacturers or suppliers user manuals or information may be

required to assist in provision of accurate information.

The SOP should be written by a member of staff who has good knowledge of the task
and has performed the particular task. Consultation with others involved in the task
may be required and is encouraged. In some circumstances additional expertise may

be required and this should be sought where applicable. Any elected Health and
Safety Representatives are encouraged to be involved in the process.

Use of Form WHS08 Development of Safe Operating Procedure is recommended.

This form may be modified to meet individual workplace needs. For hazardous
chemicals form WHS12 Chemical process risk assessment and control incorporates an
SOP development section.

SOPs should include:

I.
II.

The purpose of the work or process

Any legislative information or standards that are appropriate and have been
considered in the SOP process

III.

Definition of any specialised or unusual terms

IV.

specific information regarding the potential hazards and associated risks of the task

V.

Precautions required to eliminate or adequately reduce the risk prior to commencing

the task

VI.
VII.
VIII.
IX.
X.

Personal protective equipment to be worn while undertaking the task

The environment where the task should be undertaken
Clear and simple instructions for undertaking the task described in a safe manner
Correct environmental, cleanup and waste disposal measures
Emergency procedures and shutdown

How to prepare an SOP

I.

Sequence of Job Steps

Break down the task or operation into the basic steps to complete the work task and/or
operate the item of plant/equipment. For example, what is done first, what is done
next and so on.
Record each step of the task in the order of normal sequence, making sure you
describe what is done, not how it is done. As a working guide, the task description
should be contained within approximately 10 broad steps. This of course may vary
depending on the complexity and the hazardous nature of the job.

II.

Potential Hazards/Risks
For each step in the work task, list the potential hazards/risks that are reasonably
foreseeable.
The following should be explored in relation to the steps, and the person(s) doing the
task - Can they:

be struck by or contacted by anything

strike against or contact anything

be caught in, on, or under or between anything

fall from height or be exposed to falling objects

manual handling

III.

be exposed to welding rays, fumes, light, electricity or other forms of energy

be exposed to stored energy

be exposed to hazardous chemicals

Recommended control measures in SOP

For each step in the work task, list the most appropriate risk control measure that will
eliminate or minimise the risk to the person(s) completing the work task.
For each potential hazard/risk, identify and list the steps of how the work task is to be
completed, including what the operator(s) should or should not do to manage the level
of risk. Specifically describe the safe operating procedure and precautions that must
be taken for each step. Attach any appropriate information or references. An SOP may
reference other SOPs.

IV.

Personal Protective Equipment

The types of personal protective equipment (PPE) to be utilised to minimise the risk
to the person(s) undertaking the task shall be listed on the SOP.

V.

Perform the task

Test the written procedure by carrying out the task in accordance with the documented
SOP, completing the following checks:

inspect the task again

check the upstream and downstream tasks that may have an impact

seek improvement to the work method

consider all hazards at each step

ensure understanding in the work group or an individual staff member or

student of the hazards associated with each step of the procedure

reassess and modify the SOP as required

GENERAL LABORATORY STANDARD OPERATING PROCEDURES

This document represents the minimum set of guidelines for handling hazardous chemicals
on the campus. Individual laboratories or research groups are expected to develop more
detailed written procedures as specific research needs warrant and is required by 29
CFR1910.1450. Safety references, such as those listed at the end of this document, may be
useful in developing additional procedures. Supervisors and principal investigators are
responsible for complying with and/or enforcing appropriate safety and hygiene measures in
the work areas that they supervise. The CBL Safety Committee and Safety Officer are
available for consultative assistance to develop safe procedures for situations not covered in
this guide.

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:

If an injury requiring emergency medical assistance has occurred, call 911. Be

prepared to give detailed information to the emergency dispatcher. All accidents must
be reported to your immediate supervisor.

Chemical spills. If a toxic/hazardous chemical has made contact with the skin, start
flushing the area immediately and continue for at least fifteen (15) minutes. If
emergency assistance is required, call the Safety Officer at ext. 364 or 'O' for CBL
operator. Cleanup procedures for chemical spills may be specific to the hazardous
material(s) involved. For more detailed information, go to the CBL Spill Procedures
webpage.

Chemical Splash Goggles. Chemical splash goggles are required in all occupancies
where the potential for a chemical splash to the eye exists. Full face shields are
required over safety goggles when corrosive materials are used.

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

Disposal of chemicals. Hazardous chemicals must be properly packaged and labeled

for hazardous waste disposal.

Electrical. Access to electrical equipment (e.g. plugs, switches and electrical panels)
shall bemaintained free from obstructions to allow immediate access in an emergency.

Emergency eye wash/safety showers. Be certain safety showers/emergency eye

washes are properly located and 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 must
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.

Food, drink, cosmetics. Eating, drinking and the application of cosmetics are
forbidden in areas where hazardous chemicals are used. Food storage is restricted to
non-laboratory spaces such as approved office areas and/or the Nice Hall kitchen
(Bldg. 452, Room 0103). For more information, see the OSHA Sanitation Standard:
29 CFR 1910.141(g)(4).

Horseplay. Practical jokes or other behavior which might confuse, startle, or distract
another worker are 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 must be at least

thirty-six (36) inches wide. 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.

Mercaptans. To avoid false reporting of natural gas leaks, mercaptans should not be
used insuch a manner (e.g. scrubbers for effluent) that persons outside of the
laboratory could smellthe mercaptan and suspect a natural gas leak in the building.
Persons using mercaptans shouldreport these uses to the CBL Safety Committee
and/or Safety Officer prior to actual use.

Mouth pipetting. Mouth pipetting or siphoning 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. Therefore,
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.

PROCEDURE IN LABORATORY SAFETY

1. Hazard Identification

All chemical containers must have a legible, firmly attached

label showing the contents of the container.

Labels on incoming containers of hazardous chemicals must

not be removed or defaced. Any labels that are damaged must

be immediately replaced with labels containing the same

identification, warning and source information.

Material safety data sheet received with incoming shipments

of hazardous chemicals must be maintained and made readily
accessible to laboratory assistant.

A hazard review of new materials not previously used in the

laboratory must be completed under direction actual handling
of the material begins.

Chemical substances (or by-products) developed in the

laboratory are assumed to be hazardous in the absence of
other information.

2. Exposure Monitoring

Laboratory assistant exposures to OSHA-regulated substances

shall not exceed the permissible exposure limits.

Laboratory assistant or student exposure to any substance

regulated by an OSHA standard shall be measured when there
is reason to believe that exposure levels routinely exceed the
action or permissible level.

3. Medical Program

Medical surveillance, including medical consultation and

follow-up, shall be provided

exposure monitoring reveals exposure over the action level or

an OSHA regulated substance which has medical surveillance
requirements.

Whenever laboratory assistant or student develops signs or

symptoms that may be associated with a hazardous chemical
which may have been exposed to in the laboratory.

Whenever a spill, leak, or explosion results in the likelihood of

a hazardous exposure.

First aid kits are to be supplied and maintained

Where medical consultations or examinations are provided,

the examining physician shall be provided with the following
information:
-

The identity of the hazardous chemical(s) to which the

injured may have been exposed.

description

of

the

conditions

under

which

the

exposure occurred including quantitative exposure data

if available.
-

A description of the signs and symptoms of exposure

that the employee is experiencing, if any.

If the injured is transported by ambulance and is unable

to provide this information at the time of treatment,
others should accompany to the hospital.

4. Emergency Equipment

Each laboratory assistant or student shall be familiar with the

location,

application,

and correct ways

to operate

the

numbers

and

following equipment:
-

Fire extinguishers

Fire alarms

Safety showers

Eye wash stations

First aid kits

Chemical response spill kits

Emergency shut-off on equipment

Location

of

emergency

telephone

telephones

5. Waste Disposal Procedure

Broken Glass
-

Equipment (broken beakers, pipets, etc. that are waste)

should be promptly swept up and disposed of in rigid
cardboard containers. When the container is full tape it
shut. Place the box into the buildings dumpster.

Chemically-contaminated

glassware

may

require

handling and disposal as hazardous waste.

Broken Thermometers (Mercury)

-

Immediately clean up broken glass and spilled mercury

from broken thermometers. Do not handle mercury by
hand. Enclose thermometer pieces in a sealed jar with a
small amount of water over the mercury and follow
chemical waste packaging instruction.

Chemicals
-

Each person working in the laboratory is responsible to

ensure that all wastes are disposed of properly.

Hoods shall not be used for disposal (i.e., evaporation)

of volatile chemicals.

Drains shall not be used for disposal of chemicals.

Chemical waste generators are responsible for preparing

and packaging chemical waste.

6. Ventilation

Laboratory shall provide airflow into the laboratory from nonlaboratory areas and out to the exterior of the building (lab
under negative pressure in general) through fume hoods.

All laboratory doors should remain closed, except when being

used for entrance and egress.

All reactions that produce unpleasant and/or potentially

hazardous fumes, vapors, or gases must be run within local
exhaust systems (e.g., fume hoods).

Installation of local exhaust ventilation must be in accordance

with air emission regulations.

Do not install unsafe devices in hoods, such as extension

cords or electric switches that are not "explosion proof" by
design.

7. Maintenance & Inspections

Visually inspect the hood area for excessive storage and other
visible blockages.

Observe the flow alarm to ensure the device is performing

properly.

Fume hood alarm systems must not be disabled or modified.

8. Chemical Handling Procedures

Flammable Liquids
-

Hazards
i.

Vapor can form an ignitable mixture in air.

ii.

Many flammable liquids are solvents and are

potentially hazardous by inhalation.

iii.

Skin contact should be avoided, irritation or skin

absorption are possible with some chemicals in
this group.

iv.

Damage to the eyes range from irritation to

severe damage.

Controls
i.

Work in the fume hood as much as possible.

ii.

All spills must be cleaned up immediately and the

spill area properly decontaminated.

iii.

Emergency showers and eyewashes shall be used

when skin or eye contact occurs. Get first aid
attention immediately.

Corrosive Chemicals
-

Hazards
i.

Contact

with

the

skin,

eyes,

respiratory,

or

digestive tract causes severe irritation, tissue

damage, or burns. Burns may not be readily
apparent after exposure to some acids.
-

Storage

i. Store

concentrated

appropriated

trays

acids

and

bases

or plastic carrier

if

in
used

frequently.
ii. Oxidizing acids must be stored a way from organic
chemicals, paper, wood, or other flammables.
iii. Drip -tray residue must be removed daily.
-

Controls
i. In case of splashing to skin: Flush affected area
with large amounts of water for at least 15
minutes.

Remove

contaminated

clothing

and

discard during flushing process. Seek medical

attention.
ii. Never add water to concentrated mineral acids or
bases.

Reactive Chemicals
-

Hazards
i. Water sensitive - react violently in the presence of
water
ii. Pyrophoric materials - ignite in air at or below
room temperature without additional heat, friction,
or shock.

Storage
i. Water sensitive - follow label directions
ii. Pyrophorics - store in an atmosphe re of inert gas
or under kerosene ; exclude air

Controls
i. Following safety equipment will be utilized when
handling reactive chemicals.
ii. Read the container label and follow special hazard
instructions contained.

Compressed Gases
-

Hazards
i. Compressed gases contain gas under extreme
pressure. Sudden release of this energy can cause
serious injury and physical damage.
ii. Compressed gases may also be flammable, toxic,
or corrosive.

Storage
i. Compressed gases must be stored in the upright
position with caps in place and secured with a
strap, chain, base stand, or rack.

ii. Storage of quantities of flammable compressed

gases

requires

segregation

of

cylinders

and

specific storage methods.

-

Controls
i. Trans port only with cap in place on suitable
carrier.
ii. Use only appropriate fittings and regulators.
iii. Each gas type has special fittings.
iv. Use check valves and/or regulators.
v. Do not let cylinder go completely empty.

Toxic Metals
-

Hazards
i. Toxic by inhalation, ingestion, and possible skin
absorption.

Storage
i. The minimum quantity necessary should be kept
on hand.
ii. Store in specially designated area.

Controls
i. Work in the hood as muc h as po ssible.

ii. Spills should be cleaned up immediately, with the

work area properly decontaminated.
iii. Designate a specific area (and label) for hazardous
work.

Protective Equipment
Personal Protective Equipment (PPE). All personnel must wear PPE appropriate for the
hazardous chemicals used in the laboratory. The supervisor and/or PI is responsible for
providing all required PPE and assuring that the materials selected are appropriate for the
hazard(s).

Signs
Laboratories where hazardous materials or operations are present must provide an
emergency contact card, updated at least annually. This card should be posted on each
laboratory entrance. A recommended form with the information needed by emergency
responders is available from the CBL Safety Officer.

Smoking
Smoking is forbidden in all campus buildings by state law. 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 and the location of spill
response supplies. Written protocols must be developed by each supervisor and/or PI
when extremely hazardous chemicals or large quantities of chemicals are used. All
necessary personal protective equipment and spill cleanup materials must be readily
available for emergency use.

Unattended experiments
If operations involving hazardous substances are carried out with no one present, it is
the responsibility of the worker with the direction of his or her supervisor 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 must 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.

Working alone
CBL faculty, staff, students, volunteers and visitors are discouraged from working
alone in laboratories when the procedures being conducted are hazardous or

hazardous materials are involved. However, if one must work alone, it is advisable
that the individual maintain periodic contact with a colleague via telephone.