SOP Guide for Pharma

SOP for Emergency Procedures for Handling Chemical Spills at Receiving – V 2.0

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SOP for Emergency Procedures for Handling Chemical Spills at Receiving – V 2.0

Standard Operating Procedure for Emergency Procedures for Handling Chemical Spills at Receiving

Department Warehouse / Quality Assurance / Health and Safety
SOP No. SOP/RM/059/2025
Supersedes SOP/RM/059/2022
Page No. Page 1 of 15
Issue Date 01/02/2025
Effective Date 05/02/2025
Review Date 01/02/2026

1. Purpose

This Standard Operating Procedure (SOP) outlines the emergency procedures for safely handling chemical spills during the receiving of raw materials. It ensures the safety of personnel, prevents environmental contamination, and complies with Good Manufacturing Practices (GMP) and safety regulations.

2. Scope

This SOP applies to all chemical spills occurring during the receipt of raw materials at the facility. It includes procedures for managing spills of hazardous, flammable, corrosive, and toxic materials at the receiving dock and storage areas.

3. Responsibilities

4. Accountability

The Health and Safety Manager is responsible for ensuring that emergency spill procedures are implemented and personnel are trained. The Warehouse Manager ensures that spills are reported immediately, while the QA Manager assesses the impact of spills on material integrity. The Procurement Manager coordinates with suppliers if the spill is due to transportation or packaging failure.

See also  SOP for Verification and Compliance of Storage Conditions Before Receipt - V 2.0

5. Procedure

5.1 Immediate Response to Spills

  1. Identify the Spill:
    • Warehouse personnel must immediately identify the type and severity of the spill. Refer to the Material Safety Data Sheet (MSDS) for guidance.
    • If the spill involves hazardous or flammable materials, activate the emergency alarm and evacuate the area.
  2. Alert and Evacuate:
    • Notify the Health and Safety Officer, QA, and Warehouse Manager immediately.
    • Evacuate all non-essential personnel from the spill area.
    • Secure the area to prevent unauthorized access.

5.2 Spill Containment Procedures

  1. Use of Personal Protective Equipment (PPE):
    • Ensure that all personnel involved in containment wear appropriate PPE (e.g., gloves, goggles, respirators, chemical-resistant suits).
  2. Contain the Spill:
    • Use absorbent materials, spill containment kits, or dikes to contain the spill and prevent it from spreading.
    • For flammable spills, eliminate all ignition sources in the area immediately.
    • Document containment actions in the Spill Containment Log (Annexure-1).

5.3 Spill Cleanup Procedures

  1. Neutralization (if applicable):
    • If the spilled chemical requires neutralization, follow the MSDS instructions carefully.
  2. Remove Contaminated Materials:
    • Use appropriate tools to collect contaminated materials and dispose of them in designated hazardous waste containers.
    • Label waste containers clearly and document in the Hazardous Waste Disposal Log (Annexure-2).
  3. Decontaminate the Area:
    • Thoroughly clean the affected area with approved cleaning agents and decontamination procedures.
    • Ventilate the area if needed, and ensure all residues are removed.
See also  SOP for Monitoring and Evaluating Supplier Performance in Raw Material Delivery - V 2.0

5.4 Post-Spill Actions

  1. QA Assessment:
    • QA inspects the area to ensure no cross-contamination occurred and assesses whether the spilled materials can be salvaged.
    • Document QA findings in the Spill Assessment Report (Annexure-3).
  2. Reporting:
    • Complete a detailed Spill Incident Report (Annexure-4) describing the cause, containment actions, cleanup, and corrective actions.
    • Submit the report to the Health and Safety Manager and QA for review.
  3. Supplier Notification (if applicable):
    • If the spill resulted from supplier packaging or transportation failure, Procurement must notify the supplier and request corrective actions.
    • Document supplier responses in the Corrective Action Log (Annexure-5).

6. Abbreviations

7. Documents

  1. Spill Containment Log (Annexure-1)
  2. Hazardous Waste Disposal Log (Annexure-2)
  3. Spill Assessment Report (Annexure-3)
  4. Spill Incident Report (Annexure-4)
  5. Corrective Action Log (Annexure-5)

8. References

See also  SOP for Handling and Unpacking Large Bulk Material Containers - V 2.0

9. SOP Version

Version: 2.0

10. Approval Section

Prepared By Checked By Approved By
Signature
Date
Name
Designation
Department

11. Annexures

Annexure-1: Spill Containment Log

Date Chemical Name Batch Number Type of Spill Contained By Remarks
01/02/2025 Acetone A-2025-001 Flammable Spill Ravi Sharma Contained within 5 minutes

Annexure-2: Hazardous Waste Disposal Log

Date Chemical Name Batch Number Disposal Method Disposed By Remarks
01/02/2025 Acetone A-2025-001 Incineration Anjali Mehta Disposed at authorized facility

Annexure-3: Spill Assessment Report

Date Chemical Name Batch Number Impact on Material Reviewed By Disposition
02/02/2025 Acetone A-2025-001 No cross-contamination detected Deepak Joshi Rejected

Annexure-4: Spill Incident Report

Date Chemical Name Batch Number Description of Incident Actions Taken Reported By
01/02/2025 Acetone A-2025-001 Container leakage during unloading Spill contained and area decontaminated Ravi Sharma

Annexure-5: Corrective Action Log

Date Supplier Name Chemical Name Batch Number Corrective Action Taken Follow-Up Required
03/02/2025 PharmaChem Ltd. Acetone A-2025-001 Reinforced packaging provided for future shipments Yes

Revision History:

Revision Date Revision No. Revision Details Reason for Revision Approved By
01/01/2024 1.0 Initial Version New SOP QA Head
01/02/2025 2.0 Expanded spill containment procedures Compliance with updated regulations QA Head
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