Risk analysis and standard operating procedures for high-temperature and high-pressure experiments

University laboratories serve as critical bases for scientific research and talent cultivation. Safety management in these laboratories is directly associated with the safety of faculty and students, the security of national assets, and the stability of teaching and research activities. However, with the increasing complexity and frequency of experimental activities involving high-temperature and high-pressure equipment, the limitations of traditional safety-management models have become increasingly apparent. Specifically, long-standing issues such as inadequate risk identification, the lack of standard operating procedures (SOPs), or difficulties in their implementation have severely impacted safety and stability. SOPs are often dense, ambiguous, and impractical; thus, operators often fail to recognize risks, find it difficult to implement the procedures, or neglect to consult them. These pain points—namely, SOPs being “unrecognized, unusable, and unused”—represent a significant vulnerability in the safety management of university laboratories. Therefore, establishing a systematic risk analysis method for high-temperature and high-pressure equipment tailored to the university context, together with a complementary, visualized universal SOP framework, is of paramount importance. This approach can effectively resolve the aforementioned pain points, address critical management gaps, enhance the standardization of safety management, and significantly improve emergency response capabilities.

To this end, this study adopts a comprehensive and multi-faceted methodology. First, drawing upon systems theory and process safety management principles, this study divides the experimental process into three distinct yet interconnected stages: pre-experiment, mid-experiment, and post-experiment (the PMP model). Within each stage, systematic risks are systematically identified and then analyzed based on three fundamental dimensions: material hazards, equipment integrity, and human operation factors. This analytical framework is referred to as the MEH dimensions. The integration of the PMP model with MEH dimensions results in a robust 3 × 3 matrix for comprehensive risk assessment. Concurrently, to address the usability deficiencies of conventional SOPs, this study incorporates principles of visual communication design. The SOP is graphically reconstructed at two levels: at the macro level, the interface layout organizes information hierarchically and logically; meanwhile, at the micro level, visual elements utilize colors, icons, and typography to convey meaning intuitively and draw attention to critical points.

First, this study successfully constructed a PMP model for experimental process risk analysis based on the MEH dimensions, providing a structured and systematic tool for identifying potential hazards at every phase of the experiment. Second, a universal SOP framework was established comprising four core modules: equipment basic information, risk identification, general requirements, and standard steps. The adoption of visual graphic design principles—such as flowcharts for operational pathways, color-coded highlights for critical parameters and prohibited actions, and integrated tear-off emergency cards—represents a significant innovation that enhances the readability, user-friendliness, and execution efficiency of the SOP.

The universal framework described herein can be used to develop SOPs for common high-temperature and high-pressure equipment in university laboratories, such as ovens, hydrothermal autoclaves, and tube furnaces, enabling laboratory personnel to identify potential risks accurately and systematically. This approach fundamentally alters the cognitive pathway of risk identification, which previously relied heavily on individual experience and intuition, thereby reducing subjectivity and the likelihood of overlooking hazards. Consequently, it reduces the occurrence of operational errors and improves the efficiency of emergency response, effectively preventing laboratory safety accidents before they occur. Furthermore, the use of a universal SOP template that standardizes the format and core content substantially reduces safety management costs for departments and individual laboratories. It minimizes redundant efforts where each laboratory creates its own procedures from scratch, shortens the training cycle for new personnel by providing clear and consistent guidance, and ultimately enhances overall management efficiency and cultivates a stronger, more pervasive safety culture within the research environment.