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OISD-GDN-211September 2003

FOR RESTRICTED CIRCULATION ONLY

SAFETY IN PETROLEUM LABORATORIES

OISD-GDN-211

OIL INDUSTRY SAFETY DIRECTORATEGovernment of India

Ministry of Petroleum & Natural Gas

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OISD-GDN-211 September 2003

FOR RESTRICTED CIRCULATION ONLY


Prepared by:FUNCTIONAL COMMITTEE ON SAFETY IN PETROLEUM LABORATORIES

OIL INDUSTRY SAFETY DIRECTORATE7th FLOOR, “NEW DELHI HOUSE”,

27, BARAKHAMBA ROAD,

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NEW DELHI – 110 001

N O T E

Oil Industry Safety Directorate (OISD) publications are prepared for use in the

Oil and Gas Industry under the Ministry of Petroleum and Natural Gas. These are

the property of Ministry of Petroleum and Natural Gas and shall in no case be

reproduced, copied, loaned or exhibited to others without written consent from OISD.

Though every effort has been made to assure the accuracy and reliability of

data contained in these documents, OISD hereby expressly disclaims any liability or

responsibility for loss or damage resulting from their use.

These documents are intended only to supplement rather than replace the

prevailing statutory requirements.

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FOREWORDThe Oil Industry in India is about 100 years old. Due to various collaboration agreements, a variety of international codes, standards and practices are in vogue. Standardisation in design philosophies, operating and maintenance practices at a national level was hardly in existence. This lack of uniformity coupled with feedback from some serious accidents that occurred in the recent past in India and abroad, emphasised the need for the industry to review the existing state-of-the-art in designing, operating and maintaining oil and gas installations.

With this in view, the Ministry of Petroleum and Natural Gas in 1986 constituted Safety Council assisted by the Oil Industry Safety Directorate (OISD) staffed from within the industry for formulating and implementing a series of self-regulatory measures aimed at removing obsolescence, standardising and upgrading the existing standards to ensure safer operations. Accordingly OISD constituted a number of functional committees comprising of experts nominated from the industry to draw up standards and guidelines on various subjects.

The present document as guidelines on "Safety in Petroleum laboratories” has been prepared by the Functional Committee on " Safety in Petroleum laboratories”. This document is based on the accumulated knowledge and experience of industry members and the various national and international codes and practices.

It is hoped that provisions of this document if implemented objectively, would go a long way to improve the safety and reduce accidents in Oil and Gas Industry. Users are cautioned that no document can be a substitute for the judgment of responsible and experienced engineer.

Suggestions are invited from the users after it is put into practice to improve the document further. Suggestions for amendments, if any, to this standard should be addressed to:

The Co-ordinatorCommittee on

"Safety in Petroleum laboratories”Oil Industry Safety Directorate

7th Floor, New Delhi House27, Barakhamba Road,NEW DELHI - 110 001.

This document in no way supersedes the statutory regulations of the Chief Controller of Explosives (CCE),

Factory Inspectorate or any other statutory body, which must be followed as applicable.

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FUNCTIONAL COMMITTEE

NAME ORGANISATION

LEADER

Shri C.I. Roy Kochi Refinery Limited , Kochi

MEMBERS

Dr. Y.P. Rao Bharat Petroleum Corporation Limited , Mumbai

Shri J.R. Bijalwan Indian Oil Corporation Limited (R&D), Faridabad

Shri M.K. Daxini Hindustan Petroleum Corporation Limited, Mumbai

Shri P.D. Bahukhandi Indian Oil Corporation Limited (HO), Mumbai

Shri Harendra Singh Oil & Natural Gas Corporation Limited, Dehradun

Shri A.K.Barthwal Oil & Natural Gas Corporation Limited, Dehradun

Shri J.N. Buragohain Bongaigaon Refinery & Petrochemicals Ltd, Bongaigaon

Shri Shimbu Singh Indian Oil Corporation Limited, Panipat

Dr. D. Rambabu Engineers India Limited, Gurgaon

Shri P.S. Rama Rao Hindustan Petroleum Corporation Limited , Vizag

Shri Pallav Kumar Das Numaligarh Refinery Limited , Assam

Shri R.J. Patel Indian Oil Corporation Limited (MD), NR, New Delhi

Shri S.K. Verma Bharat Petroleum Corporation Limited, New Delhi

Shri G.S. Dang Indian Institute of Petroleum, Dehradun

Shri S.K. Pramanik GAIL ( India) Limited , Pata

MEMBER CO-ORDINATOR Shri Sanjeevi Ganesan. K Oil Industry Safety Directorate , New Delhi (Up to 6.5.02)

Shri D.K.Varshney Oil Industry Safety Directorate , New Delhi

In addition to above, several other experts from industry contributed in the preparation, review and finalisation of this document.

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–IV –

CONTENTS

S.No. Description Page No.

1.0 Introduction 1

2.0 Scope 1

3.0 Definitions 1

4.0 Location & Layout 3

5.0 Work Benches/ Fume Cupboards 3

6.0 Ventilation 4

7.0 Emergency Exit 4

8.0 Storage and Handling 4

8.1 Hydrocarbon Samples 5

8.2 Chemicals and Reagents 5

8.3 Glassware 6

8.4 Gas Cylinders 6

8.5 Containers/ Drums 7

9.0 Electrical Safety 7

10.0 Fire Prevention 8

11.0 Emergency Alarm System 8

12.0 First Aid 8

13.0 Disposal of Samples and Chemicals 9

13.1 Solid Waste 9

13.2 Liquid Waste 9

14.0 Ladder Safety 9

15.0 Sampling / Labeling / Tagging 9

16.0 Training 10

17.0 Personal Protective Equipment 10

18.0 Health and Hygiene 10

19.0 Operating Manual 11

20.0 Other Recommended Practices 11

21.0 References 13

ANNEXURESpecial Characteristics and Incompatibility of Common Laboratory Chemicals

14

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OISD-GDN-211 1


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1.0 INTRODUCTION:

Petroleum Testing Laboratories play a vital role in efficient functioning of the oil/gas industry. Tests are done in laboratory on samples of various streams, collected as per approved procedures, from process units/ offsite. The test results are intimated to all concerned for necessary actions.

In the Petroleum Industry, the laboratories do undertake various studies on catalysts & chemicals being used during processing and thereby help the management in decision-making about problems related to purchasing, processing and selling of the quality products as well as operational trouble-shooting. However, at terminals or depots, the laboratories are generally used for quality monitoring and certification of products.

Petroleum Laboratory interalia, handles the variety of oil & gas samples and uses a number of chemicals and reagents in the day to day testing and certification process.

This standard provides guidelines on Safety in Petroleum Laboratories, taking into consideration various physical, chemical and fire hazards in storage and handling of hydrocarbon samples, glassware, chemicals and reagents. Based on the guidelines of this standard, laboratory specific Safety manual and Operating manual should be developed. OISD-STD-114 on "Chemicals and their Handling" is a related document and would provide material specific data for the various chemicals used in Laboratory.

In the existing laboratories, for a variety of reasons, it may not be practical to comply with some of the recommendations of this standard, like those pertaining to location & layout, design of workbenches, location of CFR Engine. These guidelines shall, however, create awareness and help in selective implementation of the recommendations when major modifications are undertaken at existing installations.

2.0 SCOPE:

This document is applicable to the Quality Control laboratories of the Oil/Gas

processing / handling industries viz. refineries, gas processing plants, oil production/ marketing divisions as well as R&D Laboratories. It is a structured approach to cover all aspects on safety of persons, property & environment within laboratory. Accordingly, it supplements the safe working guidelines/ practices / instructions (verbal/written), which should be manualised using these guidelines. The scope of this document does not include sampling procedure and description of potential hazards.

These guidelines are formulated primarily for Stationery Labs. Any specific requirement for Mobile Labs may be manualised using these guidelines.

3.0 DEFINITIONS:

For the purpose of this document, the relevant terms are defined as under:

3.1 PETROLEUM LABORATORY :

It is a place where samples of petroleum products (like feed, intermediate-products, finished-products), samples of chemicals/ catalysts/ water etc, as well as those related to environment studies are tested by standard methods using standard apparatus.

3.2 OIL / GAS PROCESSING PLANT:

A plant where oil/natural gas is collected and processed to make Oil/LPG and other petroleum fractions. Loading operation,

Drilling activities and facilities upstream of the Christmas tree of a well are not covered under this definition.

3.3 TOXIC:

These substances include carcinogens, irritants or poisonous gases, liquids and solids which are irritating to or affect the health of humans.

3.4 DESIGNATED AREA:

OISD-GDN-211 2

An area, which may be used for work with “selected carcinogens, reproductive toxins or substances which have a high degree of acute toxicity”. A designated area may be the entire laboratory, a portion in laboratory or a device such as a fume hood. A designated area should be displayed prominently to reflect the designated hazard.

3.5 GAS (DRY):

A gas of such composition that large changes of temperature and pressure will not result in formation of liquid phase, e.g. gases composed essentially of hydrogen, C1 / C2 hydrocarbons or both.

3.6 GAS (WET):

A gas of such composition that small changes in temperature and pressure can cause appreciable changes in composition owing to formation of liquid phase, e.g. gases which are composed essentially of C3 and / or C4

hydrocarbons.

3.7 HEALTH HAZARD:

A substance for which statistically significant evidence is available, based on at least one study conducted in accordance with established scientific principles, that it may cause acute or chronic ill/ health effects in the exposed employees. Such substances also include carcinogens, toxic agents, reproductive toxins, irritants, corrosives, sensitizers, hepatotoxins (Chemicals that cause Liver damage), nephrotoxins, neurotoxins, agents which affect the hematopoitic systems and other such agents which can damage the lungs, skin, eyes or mucous membranes.

3.8 MSDS:

Material Safety Data Sheet that gives complete physical and chemical properties of the substance alongwith the safe handling procedure for the same.

3.9 PERSONAL PROTECTIVE

EQUIPMENT (PPE):

The device or clothing worn by a worker to protect himself against hazards at the work-site. Examples are respirators, gloves, chemical splash goggles, helmet, shoes etc.

3.10 PROCEDURE:

Procedure is the approved structured methodology for carrying out the task.

3.11 RESPIRATOR:

A device, which is designed to protect the person wearing the equipment from inhaling harmful contaminants.

3.12 SAMPLE

Sample is a representative quantity of the substance collected (by applying standard procedure) for testing as per the specified requirement of the study undertaken. Based on the procedure of sample collection, it can be a snap sample, continuous sample or a composite snap sample.

3.13FUME HOOD

Fume hood is a partially enclosed workspace that is exhausted to the outside. This facilitates safe release of hazardous gases and vapours generated in and around the hood. This serves to minimise exposure to airborne contaminants.

4.0 LOCATION & LAYOUT

4.1 Location of the laboratory shall be in line with OISD-STD-118. While selecting the location, due consideration should be given for hazards from nearby plant facilities assessed through Risk Analysis.

4.2 The laboratory should have separately earmarked rooms for

"OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of the OISD Standards/ Guidelines/ Recommended Practices."

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OISD-GDN-211 3

storage of chemicals & reagents, routine as well as retention samples, glassware & bottle washing. It is preferable to segregate testing facilities for hydrocarbons & gases, water and effluents. CFR engine room should be located in a corner. The layout on the basis of a central corridor or circulation aisle, with laboratory space/rooms on either side, is a preferred design.

4.3 Microbiological section of the laboratory should be segregated and well-ventilated for maintaining hygienic conditions.

5.0 WORK BENCHES / FUME CUPBOARDS

5.1 For good aesthetics and convenience, the workbenches should be modular (equal size), moveable and adjustable for height. They should facilitate manual work and support laboratory equipment. Workbenches should be fixture supported by cupboards & drawers with room for knee space. Bench top should be made of material resistant to fire and chemicals. Standard bench level height is 900 mm.

5.2 Standing or sitting near workbench should neither cast a shadow on the bench nor should one have to look up into the glare from the window. Workbenches should, therefore, be planned always at right angles to the window wall and lighting should be accordingly oriented. Sunscreen shades/films should be provided to minimise glare from windows.

5.3 Facilities like shelves, fume cupboard etc. should be laid as per standard engineering practices to avoid over-crowding. The reagents shelves should be easily accessible and should not be unduly high. These shelves should be provided with beading to prevent bottles falling off due to vibration. The shutter pans should be made of shatterproof / reinforced glass.

5.4 Floor should be resistant to fire & chemicals and made anti-skid. There should be no fittings on the floor that would hinder / obstruct free movement. Sinks and drains should be made of chemically resistant material and the drains should be properly trapped and vented.

5.5 Each laboratory should be provided with efficient fume cupboards, sufficiently large to permit complete enclosure of apparatus normally used and provide with a sink for the washing of the apparatus used for handling toxic materials. For Laboratories where large numbers of digestions are to be carried out, a separate enclosure equipped with efficient fume cupboard may be provided. The cupboard should not be too deep to make the access difficult. The controls of the service connections should be provided outside the cupboard. The fume cupboard should have corrosion-proof fittings. It should be adequately illuminated. It is preferable to provide a small window in the front shutter. This facilitates easy manipulation of samples / equipment inside the fume cupboard, without lifting the main shutter always. The cupboard should be designed such that there is strong upward draught even when the shutter is open and there is no chance of any fumes entering the laboratory. This can be achieved by having baffle at the back. In rooms, where work with extremely poisonous gases is done, it is advisable to have an air inlet at the bottom (balanced-draught cupboard) so arranged as to sweep everything to exhaust. For fume cupboard, the exhaust fan should be able to create a free velocity of 30 meter per minute at normal working height. Cupboard of highly toxic materials require higher face velocities.

Vapours of heavier hydrocarbons like waxy gas oil, LSHS, Furnace oil samples get condensed and deposited on the top of the fume


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OISD-GDN-211 4

hood. RCR /CCR tests, involving naked flame should, therefore, be carried out in a separate fume cupboard to prevent fire hazard.

Hot concentrated perchloric acid should be handled in separate fume cupboards where its vapour do not contact any organic matter.

6.0 VENTILATION

Effective ventilation should be ensured for instant removal of hazardous vapours generated inside the laboratory. Forced ventilation, single pass Once-through type should be considered with about 10-12 changes of whole air per hour, preferably by having in the layout a central corridor or a circulation aisle. Rooms should be cool, dry and well ventilated. Exhaust Ports for bottom ventilation should be provided, wherever heavier gases are likely to be present / generated. While designing the ventilation/ exhaust system, the following guiding points should be taken into consideration:

6.1 Exhaust facility should be capable of replenishing continuously fresh air for purging out the hazardous fumes / vapours.

6.2 The location of exhaust facility should be such that the light hydrocarbon vapours do not travel to exhaust via high temperature side of the bench.

6.3 Whenever a new test is introduced, prompt review should follow regarding its impact on the exhaust system of vapours especially from safety and corrosion angle.

6.4 Fume hoods should be located in the lab at draught free position.

6.5 Bottle washing room should be well ventilated.

7.0 EMERGENCY EXIT

7.1 Emergency exits should be provided at strategic locations. If possible, each laboratory room should have

two easily accessible, hindrance free exits.

7.2 All exits should be properly displayed and marked.

7.3 Doors to corridors from laboratory should swing in the direction of the exit.

8.0 STORAGE AND HANDLING

In a petroleum laboratory, a wide range of materials is stored and handled in appreciable quantities. It is important to group items for safe storage and proper utilization of available space.

Material Safety Data Sheet provided by the manufacturers should be used as guidelines for safe storage of any chemical being handled in laboratory.

8.01 Storage space should be full-height, to enable safe and easy access from a standing position. Storage of hazardous materials should be need-based and limited to bare minimum for carrying out the Laboratory work.

8.02 The store should be protected from heat and direct sunlight. However, it should be well lit and ventilated with proper exhaust to prevent built up of the concentration of hazardous gases.

8.03 The laboratory should have facility for segregated storage of materials in various categories, like: Inflammables such as hydrocarbon samples, Toxic, Reactive such as Chemicals & Reagents, Compressed Gas cylinders, Glassware etc. Care should be taken that incompatible materials are stored separately.

8.1 HYDROCARBON SAMPLES:

Store rooms for hydrocarbons samples requires special care due to flammable vapour generated by low boiling point hydrocarbon. These vapours, generally heavier than air, are likely to build up concentration at ground level. Bottom exhaust should be provided for release of


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OISD-GDN-211 5

such flammable vapours. The racks and flooring should be made of material, which is resistant to fire. Portable gas tester should be made available and maintained for periodically checking the presence of hydrocarbon . Smoke detectors should be installed.

Electrical fittings as well as electrical equipment should be flame-proof as per the guidelines mentioned at item No.9 under Electrical Safety.

Adequate number of portable fire extinguishers should be placed, as referred at item No.10 under Fire Prevention.

8.2 CHEMICALS & REAGENTS:

Everyone working in Laboratory should be made aware of the adverse effects of hazardous chemicals on potential exposure during their working in the laboratory.

8.2.1 Based on the compatibility of

chemicals, their storage must be planned. Specific to the requirements in each Laboratory, periodic review should be done to identify incompatible chemicals and a comprehensive and updated list of such chemicals should be maintained. An illustrative list of Incompatible chemicals is given in Annexure-I.

8.2.2 Material safety data sheet (MSDS) provided by manufacturer of the chemical should be extensively used as guidelines for safe storage and handling of any chemical being used in lab. As recommended in the MSDS, safety appliances specific to the chemical should be made available.

8.2.3 Each bottle/container, whether big or small, having chemical in it, should be properly labeled for its clear identification with name of the chemical, the concentration and the hazard colour code. The colour codes for hazards should be in line with OISD-STD-114. Such

information from original container should be transcribed on to the tags on the secondary/smaller containers like spray bottles.

The Identification tags should not get detached. New container should be immediately labeled after transferring a chemical into it. Chemical bottles and containers should be thoroughly washed and dried before disposal.

8.2.4 Container of chemicals that are highly volatile or decomposed or are moisture sensitive should be carefully opened.

8.2.5 All experiments involving use of toxic

chemical should be carried out in fume cupboard.

8.2.6 POISONOUS SUBSTANCES:

A separate documentation should be available for handling poisonous substances such as cyanides. Any such poisonous substances should be issued by the authorized person to the authorized user and proper inventory & record be maintained and updated on each transaction.

The inventory of poisonous substances should be kept bare minimum for sustaining laboratory operations.

Certain materials under normal or disaster conditions can be dangerous to living things around them. In general, the materials which are toxic or can decompose into toxic components due to contact with heat, moisture, acids or acids fumes, should be stored in a cool, well ventilated place away from direct sun light and areas of high fire hazard. These materials should be periodically inspected and monitored.

The poisonous materials used for the tests, should be disposed off according to the procedure duly approved, so as not to create environmental hazards.


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OISD-GDN-211 6

8.2.7 WATER REACTIVE MATE-RIALS:

Water reactive materials are those, which react spontaneously in contact with water. It is hazardous to fire fight these chemicals, using water; instead DCP should be used. An illustrative list is given in Annexure-I.

8.2.8 X-RAY TUBES / RADIO ISOTOPES

X-ray Tubes / Radio Isotopes should be handled as per guidelines of the equipment manufacturer.

8.3 GLASSWARE:

8.3.1 Awareness should be created that glassware is likely to break if handled roughly. All pieces of an apparatus should be clamped and supported properly to prevent their falling apart with slight bump and endangering the worker as well as experiment.

8.3.2 Operating manual should cover the precautions and right methodology for safely cutting a glass rod or tube, as explained in the IS-4209 on “ Code of Safety in Chemical Laboratories.

8.3.3 All glass fractures should at once be fire polished so as to round off the sharp corners.

8.3.4 While pushing a glass tube through a rubber bung, leather gloves should be worn or the glass tube should be held in a cloth. If possible, the tube can be moistened from outside before insertion.

8.3.5 Bottles of colourless glass should not be left on benches where direct sunlight may fall. This is to prevent fire hazard due to glass acting as lense and focusing sunlight on certain spots.

8.3.6 Glassware should not be stored near the edge of the shelves. The large and heavier glassware should preferably be stored in lower shelves.

8.3.7 Conventional laboratory glassware should not be pressurised or vacuumised.

8.3.8 Glassware should be inspected before use. Broken, chipped or badly scratched glassware should be discarded.

8.3.9 Cleaning of Glassware: A gentle pressure is applied for cleaning the glassware. Correctly designed brushes are used to clean glassware. New glassware is soaked several hours in acid water solution before washing. Water and recommended detergent is normally used for cleaning most of the glassware.

8.3.10 Laboratory floor should be kept free of any glass apparatus or glass bottles.

8.4 GAS CYLINDERS:

8.4.1 Compressed Gas cylinders should be chained or strapped and placed outside the laboratory in a well-ventilated shed. This area should be readily approachable for material handling/fire fighting. Guidelines in line with OISD-STD-114 should be referred for safe handling of gas cylinders.

8.4.2 Associated gas piping and valves should be metallic and suitably designed to withstand the gas pressure.

8.4.3 The service connections for supply of flammable gases, oxidizing gases etc. inside laboratory should be provided with isolation valves one each as minimum, at the points of supply and use.

8.4.4 Associated gas piping should be neatly fixed to the wall. Piping systems, including regulators should not be used for gases other than those for which they are designated and identified.


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OISD-GDN-211 7

8.4.5 Associated gas piping should be identified and tagged at the supply point and at each discharge point with the name and colour code (as per IS: 2379) of the gases.

8.4.6 All cylinders should have valid hydro-test certificate.

8.4.7 Cylinders should be shifted with the help of trolley only. Rolling of cylinders should be avoided.

8.4.8 Pressure of high pressure cylinders should be recorded on regular basis.

8.4.9 Gas cylinders containing gases which are corrosive to cylinders or cylinder valves or the gases that may become unstable during storages, should have maximum retention period of six months. Shorter period should be considered if so specified by the manufacturer.

8.4.10 Empty cylinders should be properly tagged and kept separately from the filled ones.

8.5 CONTAINERS / DRUMS :

8.5.1 Drums should be kept tightly closed and stored outside in a shed,. These should be kept on their side to prevent infiltration of rain water and corrosion.

8.5.2 Drums should be placed on suitable racks. Arranging in tiers should be avoided.

8.5.3 Drums showing signs of leakage or corrosion or otherwise unserviceable should be promptly removed from storage area.

8.5.4 To prevent intercontamination, skin contact or spillage, while withdrawing materials from drums, proper procedure should be adopted and also incorporated in the operating manual .

9.0 ELECTRICAL SAFETY:

Hazardous Area classification within laboratory building, should be carried out in line with OISD-STD-113 and IS: 5572. Accordingly, the electrical equipment / fittings should be selected in line with IS: 5571.

Following aspects should be considered for electrical equipment/ fittings in the Laboratory:

9.1 Layout of Electrical switch room have spacing as per Indian Electricity Rules.

9.2 System and Equipment earthing should be as per IS: 3043.

9.3 Proper training should be given on potential electrical and static electricity hazards present on account of electrically operated equipment, instruments, wiring, handling of hydrocarbon etc.

9.4 Single line electrical circuit diagram of Laboratory should be displayed in the switch room.

9.5 All electrical repairs/ wiring jobs should be performed under authorised electrical supervision, in line with OISD-STD-137.

9.6 Proper PPEs should be used while carrying out electrical maintenance jobs.

9.7 Plugs, having multiple outlets, should not be used. Industrial type closed / tight metal clad fittings for plug and socket assembly should be used.

9.8 Electrical Line Clearance procedure as per OISD-STD-137 should be followed.

9.9 Earth Leakage Circuit Breaker (ELCB) of 30 milli ampere sensitivity should be provided in main circuits.

9.10 Rooms handling LPG or other flammable gases should have all flameproof fittings.

10.0 FIRE PREVENTION:


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OISD-GDN-211 8

Fire prevention is required to mitigate fire hazard due to flammable material in some quantity, always present in Petroleum Laboratories. Important rules towards ignition controls involving smoking, electrical work, open flames, handling flammable material and static electricity should be strictly followed. Fire fighting equipment and emergency exits should be kept clean and ready for immediate use.

All hot work inside the Laboratory should be performed under a valid work permit system as per OISD-STD-105.

The total laboratory should be declared a “NO SMOKING AREA” and the same should be displayed in bold letters at strategic locations.

Good housekeeping does much to prevent fires. Proper disposal of waste material and clean up of spillage are essential.

Portable extinguishers should be placed at convenient locations for ease of accessibility and visibility. The running distance to locate an extinguisher should not exceed 15 M. Atleast one portable extinguisher of each type should be placed, as a minimum, in each testing / working room of laboratory. Guidelines are given in OISD STD-116 & 117 with respect to the use of portable Fire Extinguishers in laboratory.

All employees should be trained in operation of right kind of extinguisher. If a fire starts on the job, alarm should be raised with simultaneous use of extinguisher to bring down a small blaze and promptly extinguishing it before arrival of fire squad. A delayed alarm may cause the loss of precious minute and allow a fire to grow.

After extinguishing the fire, it should be notified to the Fire & Safety for replacement of any used fire extinguishers.

Heat / smoke detectors should be provided in the Laboratory as per need. Output of the detectors should be connected to the audio/visual Alarm system of the fire station/ Main Control Room.

11.0 EMERGENCY ALARM SYSTEM

One or two manual call points should be provided at convenient locations. Hooter should be provided such that it is audible in all parts of the building. Hearing the hooter, the Laboratory personnel should assemble at identified safe location. The hooter should be tested atleast once a month for operational performance and audibility as per OISD-STD-116.

Emergency procedure should be incorporated in the operating manual. Emergency telephone numbers as well as location of assembly points should be displayed prominently at suitable locations.

12.0 FIRST AID

First aid should be provided to take care of minor injuries, burns alongwith treatment against hazard of various chemicals used in the Laboratory. First- aid should be immediately provided to the victim, even if it is a minor injury. After the first aid treatment, the victim should be shifted to nearby hospital for diagnosis/treatment giving his particulars with respect to blood group etc

Structured training should include first-aid against inhalation, ingestion, skin contamination, effect on eyes, burns, electrical shocks etc. while handling of hazardous materials including chemicals. List of persons having taken training on first-aid should be displayed.

13.0 DISPOSAL OF SAMPLES AND CHEMICALS:

A waste disposal scheme should be developed for safe disposal and incorporated in the laboratory operating manual. Waste materials generated in a laboratory can be broadly classified as ‘Solid Wastes’ and ‘Liquid Wastes’. While the leftover gas samples like fuel gas should be discharged to safe height through the fume hood.

13.1SOLID WASTES:


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Garbage dumped eventually ends up in the environment. All solid wastes generated in a laboratory should, therefore, be carefully screened and segregated based on their toxic effects to device proper disposal methodology / procedure. Non-hazardous waste like, broken glassware, paper towels, empty containers etc. can be safely disposed into a garbage after ensuring that they are free from hazardous, toxic, flammable or highly reactive chemicals.

Segregated Hazardous waste including toxic chemicals, should be properly labeled and disposed as per the safe disposal scheme which is duly approved for meeting the statutory requirements..

13.2 LIQUID WASTES:

Majority of the wastes generated in a laboratory is in the liquid form. Further, liquid wastes can be divided into ‘Flammables’ and ‘Aqueous Wastes’.

13.2.1HYDROCARBONS (FLAMMABLES):

Hydrocarbons that are immiscible in water, form a layer which can be carefully decanted into safety cans. Liquid hydrocarbon leftover of the samples after testing, should be collected in separate safety cans. The quantity of flammable liquid stored in safety cans should be minimum possible. Cans should be kept at safe distance for periodic collection.

Approved procedure should be incorporated in the operating manual for organized safe disposal of hydrocarbon waste. This should consider recovery of hydrocarbon in the bottle washing room. For laboratories attached to Process Units where oil recovery system is provided, liquid hydrocarbon leftovers should routed to the recovery system through a dedicated line.

13.2.2 AQUEOUS WASTES:

Solutions of miscible hydrocarbons and water should be diluted significantly before disposing. However, a safe disposal procedure for aqueous waste should be developed which complies to all the statutory norms.

14.0 LADDER SAFETYA ladder is primarily a means of gaining access to a work place. The foot of the ladder should be properly supported on firm surface and the top end should be securely fixed to prevent its slippage. The ladder should be strong enough for the work. At a time, only one person should use the ladder. The ladder should be checked periodically for its fitness. The ladder should extend at-least one meter above the platform for landing place. The ladder should be placed at suitable safe angle to minimize the risk of slippage (ideally about 75o angle to the horizontal). The heavier objects should not be carried up the ladder.

15.0 SAMPLING / LABELING / TAGGING Samples are taken for the purpose of securing representative quantities from a part or from the bulk of the material to be tested. The safe procedure and precautions required for ensuring representative character of the sample collected is not under the scope of this guidelines. It should be developed and incorporated in the operating manual of the laboratory and the same be followed strictly. All samples should be properly tagged with date, time, type of product, source and test required.

16.0 TRAINING

The laboratory should have a Training Policy for its personnel as per the need to keep them update in knowledge and their responsibility towards safety. Training should have its objective, purpose, scope and accordingly, its course content should be designed in line with OISD-STD-154. The training module should cover hazards associated with handling of toxic materials, Fire & Safety and First-aid. Familiarization of the new incumbents should cover the operations as well as aspects on safety. After


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training, competency of participants should be assessed by the management’s representative followed with issuance of certificate to them on training. Fire & Safety and First-aid training should be given atleast once a year and record should be maintained in laboratory as well as training centre.

The training needs should be identified, on following considerations:

a. Change in the technology

b. New tests / studies / new chemicals

introduced.

c. Change in the Quality system /

specifications.

d. Transfer / Job rotation.

e. Change in the responsibility

f. Educational qualifications

g. Past work experience

h. Previous training programmes

attended

i. Future requirementsj. Lessons learnt from incidents

17.0 PERSONAL PROTECTIVE EQUIPMENT

It is necessary to equip the laboratory with personal protective equipment for using them appropriately by the personnel while handling hazardous substances to minimize the risk of hazards. These should be properly placed and well maintained. A defective equipment should immediately be attended to. The following equipment should be available for personal protection in line with OISD-STD-155:

17.1 Safety goggles and face/fume masks should be used appropriately.

17.2 Suitable type of aprons of PVC, rubber or cotton should be used to protect against specific hazards.

17.3 Protective gloves made of cotton, rubber, PVC, etc. should be worn

while handling sharp objects or hazardous substances including chemicals, glassware etc.

17.4 Proper gloves and face shield to be worn while handling extremely low temperature items and materials like solid carbon dioxide or liquid nitrogen.

17.5 Equipment like fire blankets, eye wash devices, safety showers, breathing apparatus, helmets, first-aid kit and gas masks should be available for specialized protection and all personnel should be aware of their location and use. Equipment should be checked and maintained regularly.

17.6 Earmuffs should be used in noise prone area like CFR engine rooms.

18.0 . HEALTH & HYGEINE

Adequate information about safety hazards of chemicals should be made available to the users through MSDS and Operating Manual. Accordingly, correct precautionary measures should be fully understood. All Laboratory personnel should have knowledge about the biological and medical aspects of the chemicals, they use.

Occupation Health Guidelines as per OISD-GDN-166 should be followed. Material Safety Data Sheet of all chemical used in the Laboratory should be prepared as per OISD-STD-114. In general, hydrocarbons, have low to moderate toxicity which may become acute under prolonged / repeated exposure and unhygienic conditions. Higher boiling hydrocarbon can give rise to chronic affect. The following general precautions should be taken:

18.1 Eatable should not be stored in areas where exposure to toxic material is likely.

18.2 Hands should be washed before eating and clothes should be changed immediately if they get soaked with oil or chemical and


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OISD-GDN-211 11

affected part of the body should be flushed with water.

18.3 Skin contact or inhalation of harmful substances should be avoided.

19.0 OPERATING MANUALEach laboratory should develop an operating manual containing details specific to its requirement. However, as a broad outline it should cover following areas :

1. Safety Policy

2. Layout plan

3. Organogram on Disaster Management

4. List of all the tests conducted with clear reference on the test method against each test.

5. Fire & Safety with details on fire prevention and facilities for extinguishing the fire.

6. First-Aid.

7. Locations of all detectors, Fire extinguishers, Eye wash facility etc.

8. Single line diagram of Electrical circuit

9. Handling of glassware

10. List of non-compatible materials including reactive, oxidising, water reactive materials etc.

11. Methodology for Safe disposal of Waste generated.

12. Guidelines on Health & Hygiene

13. Recommended practices

In addition to the Operating Manual, the laboratory should develop a Pocket Manual as well, containing emergency handling, Do’s & Don’ts, First-aid chart, use of PPEs, use of

various types of Fire Extinguishers, Organogram of Disaster Management along-with Telephone numbers, Roles & Responsibilities of the personnel during emergency etc..

20.0 OTHER RECOMMENDED PRACTICES

20.1 The entire laboratory should be declared a "NO SMOKING ZONE" and should be prominently displayed.

20.2 No employee should work alone in a laboratory while performing a task that is considered usually hazardous in nature.

20.3 A new test should be introduced only after review of the associated hazards, documentation and training.

20.4 For operating equipment, the recommendations of the manufacturer should be followed.

20.5 Rubber tubing used inside the laboratory for connecting equipment should be periodically checked alongwith the associated valves and replaced, to prevent leakage of flammable gases. Checking of leakage should be carried out with soap solution.

20.6 All documents related to statutory regulations should be retained for an approved period.

20.7 Storage of dangerous / poisonous liquid should be minimal, just to sustain the laboratory work. The same should be documented under the laboratory procedures.

20.8 All incidents (near-miss, minor and major) should be investigated for follow-up corrective measures.

20.9 Proper documentation should be maintained for safe disposal of chemicals/catalysts etc. and also to prevent their post-expiry use.


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OISD-GDN-211 12

20.10 “Sniff-testing” should be avoided.

20.11 LPG after various tests (especially vapour pressure test) should be released slowly keeping the nozzle of the bomb in free space. Care should be taken not to keep any hot body close to the disposal place.

20.12 Heavier hydrocarbons like waxy gas oils, LSHS, Furnace oils samples should be melted in steam/hot-water bath or constant temperature oven for testing and cleaning of the containers. Hot plate should not be used for melting purpose etc.

20.13 All experiments involving use of toxic chemicals should be carried out in a fume cupboard.

20.14 Eating should be allowed only at the identified place, from hygienic angle.

20.15 GENERALHOUSEKEEPING

House keeping in following working areas should be given special attention:

All passages like stairways, hallways, passageways, access to emergency equipment, emergency exits should be maintained dry and clear of any obstructions.

All Exits should be properly displayed /marked.

No combustible material should be stored under stairways.

Materials should be properly stacked at specified locations.


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21.0 REFERENCES

1 OISD-STD-113 on "Classification of Area for Electrical Installation at Hydrocarbon and Handling Facilities"

2 OISD-STD-114 on "Hazardous Chemical Data"

3 OISD-STD-116 on "Fire Protection Facilities for Petroleum Refineries and Oil/ Gas Processing Plants".

4 OISD-STD-117 on "Fire Protection Facilities for Petroleum Depots and Terminals".

5 OISD-STD-118 on "Layouts for Oil and Gas Installations"

6 OISD-STD-137 on "Inspection of Electrical Equipment"

7 OISD-STD- 154 on "Safety Aspects in Functional Training"

8 OISD-STD-155 on "Personal Protective Equipment"

9 OISD-GDN-166 as "Guidelines for Occupational Health Monitoring in Oil and Gas Industry"

10 IS:2379 on "Specification for Colour Code for Identification of Pipelines"

11 IS:3043 on "Standard for Code Practice for Earthing"

OISD-GDN-211 14

12 IS:4209 on "Code of Safety in Chemical laboratories"

13 IS: 5571 as "Guide for Selection of Electrical Equipment for Hazardous Area",

14 IS:5572 on "Classification of Hazardous Area (Other than Mines) for Electrical Installation"

15 Occupational Safety Health Administration (OSHA) Standards

Hand book of Laboratory Safety, 3rd Edition, Editor: A Keithfurr, CRC Press, 1990.16

Annexure-I

SPECIAL CHARACTERTICS AND INCOMPATIBILITY OF COMMON LABORATORY CHEMICALS Safe handling of chemicals require careful consideration of relevant characteristics like spontaneous ignition, flash point, decomposition with catalyst and heat, explosive nature, reactive, oxidising nature etc.

An illustrative list of chemicals predominantly used in the Petroleum Laboratories and requiring careful attention during handling and storage, is given in this Annexure. This list is, however, not exhaustive and every Laboratory should carry out in depth review of various chemicals used and put a comprehensive list in their Operating manuals. The list should be periodically updated.

Chemicals acting as Oxidizing Agents:

1) Aluminium Nitrate 2) Ammonium per sulphate

3) Barium chlorate

4) Barium peroxide 5) Calcium Chlorate 6) Calcium Nitrate7) Calcium peroxide 8) Cupric Nitrate 9) Hydrogen peroxide10) Lead Nitrate 11) Lithium Hypo

chlorite12) Lithium Peroxide

13) Magnesium Nitrate 14) Magnesium per chlorate

15) Magnesium peroxide

16) Nickel Nitrate 17) Nitric Acid 70% or less

18) Perchloric Acid 60% or less

19) Potassium chlorate 20) Potassium dichromate

21) Potassium Nitrate

22) Potassium per sulphate

23) Silver Nitrate 24) Silver Nitrite


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OISD-GDN-211 15

25) Sodium perborate 26) Sodium per chlorate 27) Sodium per sulphate28) Strontium chlorate 29) Strontium Nitrate 30) Strontium Nitrite31) Thorium Nitrite 32) Thorium Nitrate 33) Zinc chlorate34) Zinc peroxide 35) Phosphorus

pentoxide

Chemicals having property of Spontaneous Ignition:

1. Calcium Hypo chlorite 2. Chromic Acid

3. Hydrogen peroxide (27.5 – 52%) 4. Nitric Acid

5. Potassium bromate 6. Potassium permanganate

7. Sodium Chlorite (> 40%) 8. Sodium peroxide

9. Sodium permanganate 10. Trichloro iso-cyanuric Acid

11. Sodium dichloro-iso-cyanurate 12. Pyrophoric iron

Chemicals which decompose with Catalyst or heat:1. Ammonium Dichromate 2. Hydrogen peroxide (52 – 91%)

3. Calcium Hypo chlorite (> 50%) 4. Perchloric acid (60 – 72.5%)

5. Potassium dichloroisocyanurate 6. Sodium dichloroisocyanurate

Chemicals causing Explosive reaction on exposure to catalyst, heat, shock or friction:

1. Ammonium per chlorate 2. Ammonium permanganate

3. Perchloric Acid 4. .Potassium super oxide.

Chemicals incompatible in presence of certain chemicals :

Chemical Incompatible with

Acetic Acid Chromic acid, Nitric acid, hydroxyl containing compounds, ethylene glycol, perchloric acid, peroxides and permanganates.

Acetone Concentrated sulphuric acid and nitric acid mixtures or chloroform and basesAcetylene Copper tubing, halides, silver, mercury and their compounds.Alkali Metals Aluminium, calcium, lithium, magnesium, potassium, and sodium with water or

chlorinated hydrocarbon, carbon-di-oxide, halogens.Ammonia Mercury, halogens, calcium, hypo chlorite, Hydrogen fluoride.An-hydrous Aniline

Nitric acid and Hydrogen peroxide.

Azides AcidsBromine Ammonia, Acetylene, butadiene, Butane, Hydrogen, Sodium carbide, turpentine.Chlorates Ammonium salts, acids, metal, powders, sulphur, finely divided organic and combustible


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OISD-GDN-211 16

materials.Chromic Acid Acetic acid, alcohol, camphor, flammable liquids, glycerol, naphthalene.Chlorine Ammonia, Acetylene, Butadiene, benzene and other petroleum fractions, hydrogen,

sodium carbides, powdered metals.Copper salts Acetylene, Hydrogen peroxide.Cyanides AcidsEthylene diamine

Greater than 3% with methylene chloride (explosive)

Flammable Liquids

Ammonium Nitrate, Chromic Acid, hydrogen peroxide, Halogens, Nitric Acid, sodium peroxide.

Hydrocarbons Halogens, Chromic Acid, peroxide.Hydrogen peroxide

Copper, chromium, irons most metals and their salts, flammable fluids, aniline, Nitro methane.

Hydrogen Sulphide

Nitric Acid and Oxidizing gases

Iodine Acetylene, AmmoniaMercury Acetylene, HydrogenMethylene Chloride

Greater than 3% Ethylene diamine (Explosive)

Nitric Acid Sulphide, flammable fluids or gases which are readily nitrated.Oxygen Oils, grease, hydrogen, flammable liquids, solids and gases.Oxalic Acid Mercury, silver.Perchloric Acid Acetic anhydrides, alcohol, organic materials. namely wood, paper, grease & Oils.Phosphorus Air, alkalis, oxygen, reducing agents.Phosphoruspentoxide

Water

Sodium Carbon di-oxide, carbon tetrachloride, water. Any oxidizable substances, acetic acid, acetic anhydride

Sodium peroxide Carbon di-sulphide, glycerol, ethylene glycol, ethyl acetate, methanol.Sulphuric Acid Potassium Chlorate, Potassium per chlorate, Potassium permanganate.

Certain chemicals produce toxic products in presence of other chemicals:

Chemicals Should not be Stored with

If stored, possible toxic substances it produces

Amides Acids Hydrogen Amide

Cyanides Acids Hydrogen Cyanide

Hypo chlorites Acids Chlorine or Hypochlorous Acid

Nitrates Sulphuric Acid Nitrogen dioxide

Nitric Acid Copper, Brass, Heavy metals Nitrogen Dioxide

Nitrites Acids Nitrous Fumes

Phosphorus Caustic Alkalies, Reducers Phosphine

Selenides Reducers Hydrogen Selenide

Sulphides

Acids Hydrogen Sulphide


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OISD-GDN-211 17

Telhurides Reducers Hydrogen Telluride


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