Below is a formal, GMP-aligned Emergency Procedures module for Supercritical CO₂ Extraction (SFE). This is written so it can be used directly in SOPs, training manuals, audits, and safety drills.
Emergency Procedures for Supercritical CO₂ Extraction (SFE)
1. Emergency Response Principles (NON-NEGOTIABLE)
- Life safety first, equipment second
- Evacuate before investigating
- Do not attempt repairs during an emergency
- Only trained personnel may restart systems after an incident
2. Emergency Situations Covered
- CO₂ leak or alarm
- Over-pressure or pressure excursion
- Rapid depressurization / uncontrolled venting
- Equipment failure (vessel, tubing, valve)
- Power failure during pressurized operation
- Fire or explosion nearby
- Personnel exposure or injury
3. CO₂ Leak or CO₂ Alarm (MOST CRITICAL SCENARIO)
Immediate Actions
- Stop work immediately
- Evacuate the area
- Move upwind and uphill if possible
- Do NOT attempt to locate the leak
- Activate emergency ventilation
- Close access to affected area
Re-Entry
- Only after:
- CO₂ sensors read normal (<0.5%)
- Safety officer authorization
- Never re-enter alone
4. Over-Pressure or Pressure Alarm
Automatic Response
- System should:
- Trigger alarm
- Shut down pumps
- Engage pressure relief systems
Operator Actions
- Stand clear of equipment
- Verify system is depressurizing safely
- Do not override interlocks
- Report incident immediately
After Stabilization
- Lock system out
- Investigate root cause (blocked outlet, valve failure, overheating)
- Document deviation before restart
5. Rapid or Uncontrolled Depressurization
Risks
- Cold burns
- Flying debris
- Noise trauma
- Seal failure
Response
- Move away from system immediately
- Allow automatic depressurization to complete
- Ventilate area
- Do not touch cold surfaces
- Report incident
6. Equipment Failure (Vessel, Fitting, Tubing)
Signs
- Loud bang or hissing
- Sudden pressure drop
- Visible frost or CO₂ plume
Response
- Immediate evacuation
- Activate emergency shutdown
- Do not re-enter until pressure is confirmed at zero
- Lock-out / tag-out equipment
- Engineering inspection required before reuse
7. Power Failure During Operation
If System Is Pressurized
- Automated systems should:
- Go to safe state
- Hold or slowly depressurize
Operator Actions
- Do not open vessels
- Monitor pressure remotely if possible
- Vent only when power and control are restored
- Treat restart as a new batch
8. Fire in or Near the SFE Area
⚠️ CO₂ does not burn, but:
- Co-solvents may ignite
- Pressure vessels may fail under heat
Response
- Trigger emergency shutdown
- Evacuate immediately
- Inform fire responders of:
- High-pressure CO₂ system
- Location of vessels and cylinders
- Do not re-enter until cleared by fire authority
9. Personnel Exposure to CO₂
Symptoms
- Dizziness
- Shortness of breath
- Confusion
- Loss of consciousness
Response
- Remove person to fresh air immediately
- Call emergency medical services
- Administer oxygen if trained
- Do NOT re-enter contaminated area
10. Emergency Equipment That MUST Be Present
| Equipment | Requirement |
|---|---|
| CO₂ detectors | Audible & visual |
| Emergency stop | Clearly marked |
| Ventilation system | Emergency mode |
| First-aid kit | Accessible |
| Oxygen | Where required |
| Emergency lighting | Backup power |
| Fire extinguishers | Appropriate class |
11. Post-Emergency Actions (MANDATORY)
- Incident report
- Root Cause Analysis (RCA)
- Corrective & Preventive Action (CAPA)
- Equipment inspection & requalification
- Operator retraining if required
- Regulatory notification (if GMP-regulated)
12. Emergency Drill & Training Requirements
- Emergency drills at least annually
- CO₂ alarm response drills
- Documentation of:
- Attendance
- Response time
- Observed gaps
- Training records required for GMP audits
13. Emergency Response Decision Tree (Simplified)
Alarm or abnormal condition → STOP → EVACUATE → VENTILATE → REPORT → INVESTIGATE → DOCUMENT → AUTHORIZE RESTART
Final Rule
No product, no data, no schedule is worth a life.
If in doubt — evacuate.
Bottom Line
Emergency procedures for SFE must be clear, rehearsed, automated, and enforced. High-pressure CO₂ incidents escalate quickly, but disciplined response prevents injury, fatalities, and catastrophic damage.
If you want, I can:
- Turn this into a posted Emergency Action Plan (EAP)
- Create a one-page emergency response flowchart
- Develop a CO₂ alarm drill script
- Customize procedures for lab, pilot, or industrial scale
Just tell me which one you want next.