"

OISD-GDN-211
September 2003

FOR RESTRICTED
CIRCULATION ONLY








SAFETY IN PETROLEUM LABORATORIES









Prepared by:
FUNCTIONAL COMMITTEE ON SAFETY IN PETROLEUM LABORATORIES










OIL INDUSTRY SAFETY DIRECTORATE
7
th
FLOOR, NEW DELHI HOUSE,
27, BARAKHAMBA ROAD,
NEW DELHI 110 001


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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.




















- II -


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FOREWORD

The 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-ordinator
Committee on
" Safety i n Petroleum laboratori es
Oil Industry Safety Directorate
7
th
Floor, New Delhi House
27, 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.

- III -




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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.

IV



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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
ANNEXURE
Special Characteristics and Incompatibility of Common Laboratory
Chemicals



14

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OISD-GDN-211 1

SAFETY IN PETROLEUM LABORATORIES

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,

OISD-GDN-211 2

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

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:

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 C
3
and / or C
4

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.

3.13 FUME 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.
OISD-GDN-211 3

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

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
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
OISD-GDN-211 4

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

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
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 &
OISD-GDN-211 5

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

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
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
OISD-GDN-211 6

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

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.

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.

OISD-GDN-211 7

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

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.

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.

OISD-GDN-211 8

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

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:

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.


OISD-GDN-211 9

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

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.

13.1 SOLID WASTES:

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 SAFETY

A 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 75
o
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.


OISD-GDN-211 10

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

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
training, competency of participants should
be assessed by the managements
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 / J ob rotation.
e. Change in the responsibility
f. Educational qualifications
g. Past work experience
h. Previous training programmes
attended
i. Future requirements
j. 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
OISD-GDN-211 11

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

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
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 MANUAL

Each 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, Dos
& Donts, 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
OISD-GDN-211 12

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

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.

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.





















OISD-GDN-211 13

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



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"
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

16
Occupational Safety Health Administration (OSHA) Standards

Hand book of Laboratory Safety, 3
rd
Edition, Editor: A Keithfurr, CRC Press, 1990.










OISD-GDN-211 14

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

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) Bariumchlorate
4) Bariumperoxide 5) Calcium Chlorate 6) CalciumNitrate
7) Calciumperoxide 8) Cupric Nitrate 9) Hydrogen peroxide
10) Lead Nitrate 11) LithiumHypo chlorite 12) LithiumPeroxide
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
25) Sodiumperborate 26) Sodiumper chlorate 27) Sodiumper sulphate
28) Strontiumchlorate 29) StrontiumNitrate 30) StrontiumNitrite
31) ThoriumNitrite 32) ThoriumNitrate 33) Zinc chlorate
34) 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. SodiumChlorite (>40%) 8. Sodiumperoxide
9. Sodiumpermanganate 10. Trichloro iso-cyanuric Acid
11. Sodiumdichloro-iso-cyanurate 12. Pyrophoric iron

Chemicals which decompose with Catalyst or heat:
1. Ammonium Dichromate 2. Hydrogen peroxide (52 91%)
3. CalciumHypo chlorite (>50%) 4. Perchloric acid (60 72.5%)
5. Potassium dichloroisocyanurate 6. Sodiumdichloroisocyanurate




OISD-GDN-211 15

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

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

1. Ammonium per chlorate 2. Ammonium permanganate
3. Perchloric Acid 4. .Potassiumsuper 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 chloroformand bases
Acetylene 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 Acids
Bromine Ammonia, Acetylene, butadiene, Butane, Hydrogen, Sodium carbide, turpentine.
Chlorates Ammonium salts, acids, metal, powders, sulphur, finely divided organic and combustible
materials.
Chromic Acid Acetic acid, alcohol, camphor, flammable liquids, glycerol, naphthalene.
Chlorine Ammonia, Acetylene, Butadiene, benzene and other petroleum fractions, hydrogen,
sodiumcarbides, powdered metals.
Copper salts Acetylene, Hydrogen peroxide.
Cyanides Acids
Ethylene
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, Ammonia
Mercury Acetylene, Hydrogen
Methylene
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.
Phosphorus
pentoxide
Water
Sodium Carbon di-oxide, carbon tetrachloride, water. Any oxidizable substances, acetic acid,
acetic anhydride
Sodiumperoxide Carbon di-sulphide, glycerol, ethylene glycol, ethyl acetate, methanol.
Sulphuric Acid Potassium Chlorate, Potassium per chlorate, Potassiumpermanganate.