Job Safety Assessment FormChem-E-Car

2009 Regional Competition – Updated January 2009

University: Arizona State University Vehicle Name: “Relanpago de Oro”

JSA Author Contact Name: Stephanie Archabal Author Email: stephanie.archabal@asu.eduFaculty Supervisor: Dr. Bryan Vogt Supervisor Email: bryan.vogt@asu.eduRevision #: 1 Revision Date: 2/13/2009

Date and location of required ChemE car safety training for current team and advisor:

Advisor __Dr. Bryan Vogt_______ Team_Arizona State University ChemE Car Team B_

Approval to Begin Construction: Advisor: __Dr. Bryan Vogt _ Date: _______________

Approval to Operate: Advisor: __Dr. Bryan Vogt_ Date: _______________

Purpose of Experiment / Equipment: Briefly describe your Chem-E-Car’s design, intended mode for operation (source of power), intended mode for control (stopping), and major hazards and their control.The Chem-E-Car will be driven by an Alkaline Battery. The Alkaline battery consists of an electrolytic Manganese Dioxide (EMD) cathode and a zinc anode. The physical state of the EMD and the Zinc are powders of small particle size. The cathode is a mix of EMD, graphite, and a 47% solution of Potassium Hydroxide (KOH). The anode is composed of zinc, Polyvinyl alcohol as a binding agent, and the KOH solution. The KOH acts as the electrolyte for the battery. The design of the battery consists of a 1 ¼ in by 2 in. square carbon steel tubing, 1 ¼ in. brass rod, plastic caps, and paper towel separators. The cathode mix is directly pressed inside the walls steel tubing where the steel acts as the positive terminal. The separators are placed inside the cathode that is pressed against the steel and then soaked in KOH. The anode mix is then placed inside the separator where the brass rod is then inserted. The brass rod is the anode collector acting as the negative terminal. There will be six of these batteries in series and placed inside a plastic container. The major hazard is the KOH that might leak from the battery. This will be control by sealing the battery with shrink wrap and then placing them in the sealed container. Loose wires will also be contained inside the plastic container of the six batteries. The stopping mechanism will be a magnesium strip that is part of the closed circuit in a Hydrochloric acid bath. Depending on the morality of the acid, the magnesium strip will react with the acid producing hydrogen and magnesium chloride, and the magnesium strip will dissipate and resulting in an open circuit, shutting down the car. The acid hazard will be contained also in a plastic container and vented to allow the hydrogen to escape.

Expected Operating Conditions:Temperature Pressure

Normal: 25C Normal: 1atmMinimum: 20C Minimum: 1atm

Ver. 1, January, 20091

Maximum: 30C Maximum: 1atm

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Disallowed Activities: All activities listed below are not allowed and will result in a multi-year disqualification of your university from ChemE car competition and possible fines.Item (a) No transport of chemicals in private, university or rental vehicles either to or from the competition.(b) Chemicals must not be stored in hotel rooms or other facilities not rated for chemical storage. Approved chemical storage will be provided at the host site.(c) No vehicle testing in hotel or dorm hallways, warehouses, or other facilities that are not designed for chemical handling. This includes your university and the competition site.(d) No improper disposal of chemicals at the conclusion of the competition. All chemicals shipped to the competition site must be disposed of in a safe and environmental fashion following all local, state and national regulatory measures. Chemical disposal will normally be provided by the host site.

Disallowed Vehicles: All of the items listed below are not allowed.Item Explanation

(a) Flames and/or smoke Both inside and outside the vehicle, except for commercial internal combustion engines. See ChemE car rules for using commercial internal combustion engines.

(b) Liquid Discharge Liquid may not be discharged under normal operating conditions.

(c) Open and/or improperly secured containers

Containing chemicals having an NFPA rating of 2 or greater. All containers with these chemicals must have secure lids and must be secured to the vehicle. All containers brought to the starting line must have lids, be properly labeled, and proper personal protective equipment must be used.

(d) Chemical pouring at starting line

Any chemicals with an NFPA rating of 2 or greater. Use a holding vessel on vehicle, with valve, to load starting chemicals.

(e) Regulated Chemicals A number of chemicals are listed by OSHA as a special hazard. See list below. OSHA has a special regulation for each chemical. See www.osha.gov for details.

(f) Highly Reactive / Unstable Chemicals

Any chemical, raw material, intermediate or product with an NFPA reactivity / instability rating of 4.

Regulated chemicals: 1asbestos, coal tar pitch volatiles, 4-nitrobiphenyl, alpha-napthylamine,methyl chloromethyl ether, 3,3'-dichlorobenzidine, bis-chloromethyl ether, beta-naphthylamine, benzidine, 4-aminodiphenyl, ethyleneimine, beta-propiolactone, 2-acetylaminofluorene, 4-dimethylaminoazo-benezene, n-nitrosodimethylamine, vinyl chloride,inorganic arsenic, benzene, 1,2-dibromo-3-chloropropane, acrylonitrile, ethylene oxide, formaldehyde, 4,4'-Methylenedianiline, 1,3-butadiene, methylene chloride.

Ver. 1, January, 20093

Personal Protective Equipment (PPE) : Check all PPE worn during operation of this Chem-E-Car. Do not list these in the procedure section.X Long Pants X Safety Glasses Hard Hat Apron

Long Sleeves X Splash Goggles Insulated Gloves Ear Protection Non-porous Shoes Face Shield X Chemical Gloves Other:      

Available Safety Equipment – Provide the location of each item shown below at your home institution where your vehicle will be operated and tested. Show the location of this equipment on your provided floor plan. If not available, type “NA” in the field.

Item LocationFire Extinguisher: Wall by Entrance to Laboratory Eyewash: Wall around corner from Entrance Safety Shower: Next to eyewashTelephone: Outside Lab entranceFirst Aid Kit: Wall by eye washSpill Containment Next to eyewashOther: Fire blanket/ERG

Next to entrance door

Spill Response Supplies - Provide the location of each item shown below at your home institution where your vehicle will be operated and tested. Show the location of this equipment on the attached floor plan. If not available, type “NA” in the field.

Item LocationSpill Kit: By the eye washFloor-Dri: In spill Kit by the eye washSpill Dikes: In spill Kit by eye washSodium Bicarbonate: On the lab cornerDrain Plugs: In sinksSpill Pillows: By the eye washMercury Spill Kit: HAZWAP departmentOther:            Other:            

Ver. 1, January, 20094

Vehicle Primary Hazards Checklist: Check the left hand column box if the hazards listed below exist on the vehicle. Then check the applicable means of control for each hazard.

Hazard (check if present)

Control

(a) Pressure Anything greater than 1 psig? Must meet all requirements below: Pressure gauge (must read to 2x max. operating pressure) Emergency relief device set to no more than 1.1 times max. operating

pressure. Relief sizing calculations must be provided. Emergency relief device in proper location. Pressure certification – see Pressure Vessel Testing Protocol Proper management system to prevent over or mis-charging.

Must have measurements or calculations to prove maximum operating pressure.See ChemE car rules for more details on these requirements.

X (b) Toxic Any chemicals with an NFPA toxicity of 2 or greater?X Doubly contained and handled properly.

X(c) Flammable Any chemicals with an NFPA flammability rating of 2 or higher?XDoubly contained and handled properly

X (d) Reactive Any chemicals with an NFPA instability / reactivity rating of 2 or 3?Chemicals with a 4 rating are not allowed.X Doubly contained and handled properly.

(e) Temperature

Any exposed surface greater than 150 deg. F or under 32 deg F? Insulation or barrier to prevent contact.

X (f) Electrical Exposed wiring and electrically energized components are ignition, electrocution, and a shorting / fire hazard. Alligator clips and twisted wire connections are not allowed – use binding posts or banana plugs for a more secure connection.X Proper electrical insulation and connections provided.

X(g) Mechanical Any fast moving parts (meshing gears, belts or chains) that are pinch hazards?XGuards present and adequate.

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Fabrication & Operation Additional Hazard Detail Check List: Check all hazards that are likely to be encountered during your Chem.-Car construction and operation. List the major source(s) of the hazard and describe how the hazard(s) will be controlled. If both construction and hazard columns are checked in an individual row, then the hazards should be identified separately for both the construction and operation.

Hazard Present During Control Method(s)1 PPE Required1

Construction? Operation?Pressure X Inside stable vice Safety glasses and Lab coatToxicity            Flammability X X Free from open flames and heat

sourcesSafety glasses and vent hood

Reactivity / Instability X Properly contained and handled Gloves, lab coat, and vent hoodHot Surfaces/ High Temp > 150 F

Cold Surfaces/ Low Temp < 0 C

           

Electrical X Inside container with no open wiring Safety gloves and appropriate toolsArc welding X Inside welding environment Welding mask and welding glovesGas welding            Lathe            Milling machine            Handheld power tools X Lab manager performed all machining Safety glasses, closed toed shoesDrill press X       Safety glasses, closed toed shoesOther mechanical hazards

           

Paint spraying            Ionizing radiation            Laser radiation            Asphyxiates            Open flames            Potential Spills X X Placed inside container with cap

And careful use with appropriate toolsGloves, safety glasses

Other:            Other:            

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Required Attachments: All attachments must be provided to the JSA reviewers and to the on-site inspectors. For electronic transfers, use only a .doc, .pdf, or .ppt file formats. Submit pictures in jpeg format.

Picture of your vehicle. For electronic file transfers use jpeg format.X Flow diagram of vehicle processLabel all valves and identify all equipment for reference in procedure.

Laboratory Floor Plan – at your home institution where the car will be tested.Identify the location of your experiment and all safety and spill response equipment.

Equipment SpecificationsInclude materials of construction, maximum temperature and pressure, standard operating values, and any other specifications important to the safe operation.

Pressure documentation, if pressure hazard checked on page 3. This should include pressure calculations, pressure testing, relief sizing calculations, pressure vessel certification and any other materials required to demonstrate that these hazards have been addressed properly.X Material Safety Data Sheets (MSDS)Include for all reactants, products and any intermediate or other chemicals which may occur.

Additional Attachments: As necessary to support safety.                        

Ver. 1, January, 20097

Chemical Information PageFill in as much data below as available. If data are not available, leave the field blank.

Chemical Quantities: List below the chemical names, concentrations, and total quantity of chemical required for the competition.

Chemical NameChemical State

Solid, Liquid, GasConcentration Required

Be sure to list units!Total Quantity Required for Competition

Be sure to list the units!Commercial battery anode

Zinc powder Zinc Oxide Carboxymethyl

cellulose

SolidSolid

Solid/liquid

99.9+% pure99.9+% pure

95% pure

120g total

Potassium Hydroxide Soln 47%

Liquid 47wt% 86.4 mL

Electrolytic Manganese dioxide

Solid 92+% pure 360 grams

Carbon (graphite) powder Solid 99.99+% metals basis 25.8 grams  Hydrochloric Acid Liquid 12 M 35 mLMagnesium Solid 99.5% .22 g                 

Chemical Properties and Hazards for ALL CHEMICALS, including reactants, intermediates and products.

Chemical NamePhysical

State S, L, G

NFPA Ratings*Incompatible Chemicals

List chemicals present within the laboratory, and any others that may come in contact.

Flash PointTemp.

Flammability Limits

H F S Sp. LFL UFLCommercial battery anode

Zinc powder

Zinc Oxide Carboxymeth

yl cellulose

Solid

SolidSolid

0

21

1

00

2

00

  

- Water, sulfur, halogens, strong oxidizing agents, lower molecular weight chlorinated hydrocarbons

- -

8

Potassium Hydroxide Soln 47%

Liquid 3 0 1 - - - -

Electrolytic Manganese dioxide

Solid 2 0 1 Ox Organic Materials, combustible materials, aluminum powders, chlorates, chlorine trifluoride, hydrogen peroxide, permonosulfuric acid, potassium azide, rubidium acetylene carbide, sodium peroxide, sulfur, other oxidizable materials

- - -

Carbon (graphite) powder

Solid 1 1 0 E - 93.3C - -

Hydrochloric Acid Liquid 3 0 2 Highly reactive strong bases,metals, metal oxides, hydroxides, amines, carbonates, and other alkaline materials (cyanides, sulfides, sulfites, and formaldehyde)

- - -

Magnesium Solid 2 3 1    - - - -                                            *NFPA Ratings: H – Health, F – Flammability, S – Stability, Sp. – Special

Chemical Toxicology, Regulation and Disposal: List the same chemicals that appear above, in the same order.

Chemical NameToxicology Hazardous

Waste Number

OSHARegulated? Personal Protective Equipment

Specific to this ChemicalTWA PEL Other

Commercial battery anode

Zinc powder Zinc Oxide Carboxymeth

yl cellulose

10 mg/m35 mg/m310mg/m3

15mg/m315mg/m3

- -

VENTILLATION SYSTEM, gloves, lab coats

Potassium Hydroxide Soln 47%

- - - - gloves, lab coats

Electrolytic Manganese dioxide

5 mg/m3 - - 29 CFR 1910.1200

X gloves, lab coats, Ventilation System

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Carbon (graphite) powder

2 mg/m3 - - - -

Hydrochloric Acid - 5 ppm - - Gloves, ventilation, lab coatsMagnesium 10mg/m3 - - - -                       

Chemical Reactions: Provide details below on any chemical reaction(s) that occur in your process. Please show the species involved, the stoichiometry and the heat of reaction, if available. Also list side reactions and any other reactions that may impact safety.

2MnO2 + Zn + 2H2O à 2MnOOH + Zn(OH)2 Mg + 2HCl -> MgCl2 +H2

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Job Safety Assessment FormSafe Operating Procedures Page

Provide step-by-step details for each of the sections shown below. Identify the hazards, the control methods and the personal protective equipment (PPE) required. Provide adequate detail so that the reviewers of this document will have adequate understanding of your procedure to pass judgment on the safety of your vehicle.

The Emergency Shutdown section should have only one or two steps required to stop your vehicle and bring it to a safe state. The Start-Up Procedure section should list all the steps required to prepare your chemicals and vehicle.The Run Time Procedure should describe all steps to operate your vehicle at the starting line of the competition.The Shutdown Procedure should describe the steps normally taken to shutdown your vehicle at the end of your competitive run.The Cleanup / Waste Disposal section should list all the steps required to clean your vehicle of all chemicals and proper chemical disposal.

Sequence of Steps Potential Hazards Procedure to Control HazardPPE or Equipment

RequiredEmergency Shutdown             Disconnect Circuit Thermal/Electrical GloveStart-up Procedure

1. Mix Dry ingredients in motor/pestle (60 g MnO2, 4.3 g Carbon, .7 g poly(ethylene-alt-maletic)

2. Add 6.4 mL KOH to make a paste3. The mixture was added to the casing, and then

packed to create a hollow cavity.4. take our anode from commercial battery and

separate zinc anode mix from separators5. allow separators to dry6. place separators inside battery with packed cathode

and then place zinc anode mix inside 7. Add a few drops KOH to top of the cathode section8. cap (cap contains brass pin)9. Place 11.5” magnesium strip in stopping container**casting is rectangular of Carbon steel of 2”x1.5”1.5”**

Skin Irritant, repertory, caustic burns

Perform in hood, be cautious of chemicals Gloves, long clothing, goggles

Run Time Procedure     1. Safety toggle switch

2. Enter predetermined HCl into waterSkin irritant Syringe Gloves, goggles

Shutdown Procedure

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Turn off switch                  Cleanup / Waste DisposalRemove acid water mixture Skin irritant gloves

Batteries are surrounded by copper plates and laced into a closed Plexiglas container that is velcro-ed to the car. The stopping mechanism is enclosed in a smaller, separate Plexiglas container that is vented. The stopping mechanism is also velcro-ed to the car.

The battery cap and brass nail fit snugly.

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Flow Diagram

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