24 Safety in Laboratories

RELIANCE INDUSTRIES LIMITED
ALLAHABAD MANUFACTURING DIVISION

SAFETY MANUAL
DOC. TITLE SAFETY IN LABORATORIES
DOC. NO. SM/24 Date: 01.10.2007
REVISION NO. 00 Page: 1 of 11
PREPARED BY : REVIEWED BY: APPROVED BY:
C.S.GUPTA ASHOK AGRAWALA M.P.GARG
SAFETY IN LABORATORIES
SAFETY MANUAL
DOC. NO. SM/24 Date: 01.10.2007
Index
Sl.No. Description Page No.

1.0 Objective 3
2.0 Introduction 3
3.0 Scope 3
4.0 Procedure 3
4.1 General safety rules 3
4.2 Hygiene 5
4.3 Eye protection 5
4.4 Use of hood 6
4.5 Procedure for taking samples 6
4.6 Safety in sample bomb handling 8
4.7 Safety in extruder/injection molding/hydraulic press 9
4.8 Safety in handling of lab instrument 9
4.9 Waste disposal 10
4.10 Safety in handling gas cylinders 10
4.11 Safety in handling glassware 11
4.12 Handling emergency 11
4.13 Safety audit 11
SAFETY MANUAL
DOC. NO. SM/24 Date: 01.10.2007
1. OBJECTIVE:
The main intent of this document is to create a healthy and safe working atmosphere
In laboratories to avoid unsafe acts & to follow the good laboratory practices.
2. INTRODUCTION:
Most of us are aware of the hazards, but some basic habits should be cultured in ourselves to be a
professional chemist like use of proper safety equipments & maintaining safe work environment.
Statistics show that glass, high temperature and dangerous chemicals are the most frequent
causes of accidents in the laboratories. Safety is a day-to-day need in the chemical industry and
one cannot just overlook the importance of safety measures while working in laboratories.
Though laboratories are considered less hazardous as compared to plants, there are potential
hazards involved in handling chemicals, other activities and the same can be minimized knowing
how to handle chemicals properly and then putting that knowledge into practice.
It must be noted that the accidents in the laboratory can be mainly due to hydrocarbon leakages,
electrical sparks/shocks, spillage and splash of solvents, acids, alkali, and other hazardous
chemicals. Various precautions health, fire, spills, disposal, first-aid etc. are covered in the safety
data sheets on different hazardous chemicals attached with this safety manual which will be of
help to all to maintain safe environment.
3. SCOPE – All laboratory buildings.
4. PROCEDURE:
4.1 General safety Rules
(a) All the tests and experiments must be carried out by following the safe methods as laid
down in this manual or as mentioned in the SOP’s for testing / calibration / sampling or
as directed. Performing any test or experiment outside the scope of approved laboratory
facilities and procedures or without permission of Supervisor is forbidden.
SAFETY MANUAL
DOC. NO. SM/24 Date: 01.10.2007
(b) Before leaving work, ensure all appliances and equipments not required to be used, are
properly turned off, disconnected or otherwise rendered safe; particularly electrical / gas
equipment. See that the glasswares used for test and samples including sample cylinders
are kept at designated place after test.
(c) Never distract attention of another employees unnecessarily. Employees should give
their fullest attention to their job at all times to prevent accident and mistakes.
(d) Do not allow gas to escape from gas burners. It can cause explosion hazard. When gas
burner is lighted, open gas tap and apply lighter spark simultaneously. and in the work
area.
(e) Carry the sample / reagent bottles in the carriers to avoid slippage from hand. While
handling any 2.5 liter bottle never hold it at its top. Always put your palm at the bottom
and one hand to top to have firm grip.
(f) Test requiring use of open flame in laboratory shall be restricted and allowed only in
designated locations.
(g) Use hand gloves, apron and eye protections while handling acids and corrosive
chemicals.
(h) When drawing samples of toxic and corrosive products use proper protective equipments.
(i) All the samples should be collected by sampler in presence of operator in-charge of the
plant for the purpose of analysis.
(j) All containers of chemicals and samples should be labeled clearly and correctly. All
unlabelled materials should be discarded under the direction of the lab technician / lab in
charge.
(k) Liquefied hydrocarbon samples must not be stored in glasswares as it can get pressurized
and burst and lead to unsafe condition.
(l) Draw samples slowly and cautiously, particularly the samples with high temperature and
pressure.
(m) When taking samples, never stand on the side of the opening where escaping vapors or
liquid will flow towards you. Keep sampling valves, closed at all the times, except when
actually sampling.
(n) Cork borer shall be kept sharp and lubricated with glycerol-alcohol mixture when used.
Always bore through from both sides to meet in the center and rotate the stopper
occasionally during the boring o aid in making perpendicular hole. Do not hold the
stopper in the palm while boring.
SAFETY MANUAL
DOC. NO. SM/24 Date: 01.10.2007
(o) Before inserting glass tube into stopper hole, moisten the hole and the tube with water or
glycerin. Hold the stopper firmly with the thumb and forefinger and gradually push it by
rotating the tube, holding with thick cotton cloth.
(p) Air pressurizing system in the laboratory should be kept operative to maintain positive air
pressure within the room. This will prevent entry of flammable gases from outside.
(q) All laboratory personnel must be familiar with location and the use of fire extinguishers,
safety showers, eye baths, fire blankets, gas masks and electrical switches. Fire/Safety
equipment should not be blocked by placement of materials.
(r) When using compressed air for cleaning/drying glassware, slowly open the air valve.
Excess pressure can cause hazard.
4.2 HYGIENE
The following rules should be observed with regard to personal and

general hygiene:
1. Food must not be stored in laboratory fridges or iceboxes or in ovens and must not be left
on laboratory benches. Prior to taking meals, hand must be washed thoroughly with soap
and water.
2. It is advisable to protect hands with barrier cream before handling solvents.
3. Hands should be washed immediately after handling chemicals.
4. Laboratory glassware must not be used for drinking water purposes.
5. Do not use compressed air to clean clothing or the skin.
6. When new or unfamiliar chemicals are encountered, make every effort to determine their
hazards before handling them. In case, it cannot be determined, treat them as toxic or
otherwise hazardous material.
4.3 EYE PROTECTION
All laboratory personnel should use safety goggles (spectacle type) while doing following
jobs: -
1. Working with any glass apparatus maintained under positive pressure or under
negative pressure such as vacuum distillation etc.
SAFETY MANUAL
DOC. NO. SM/24 Date: 01.10.2007
2. Using ammonia (strong or dilute) as well as caustic solutions as eye is highly

sensitive to alkalis and slash in eyes may lead to serious injury to eyes.
3. Opening bottles of any acids, alkalis or other corrosive chemicals. Pressure is
frequently built-up especially during warm weather.
4. Opening glass stoppers of containers containing corrosive material can cling towards
the glass stoppers and splatters upward on opening, creating hazard to the opener’s
eyes.
5. While diluting concentrated acids, especially sulfuric, the heat generated often results
in splattering. This hazard can be mainly reduced by adding the acid to water with
slow stirring.
6. Working with perchloric acid or its salts. It should be remembered that certain
commercial drying agents are salts of perchloric acid. Perchloric acid or perchlorates
will explode on contact with organic matter.
7. Working with strong alkalis and acids either solid or in solution.
8. Exposed to danger of chemical splashing particularly during sampling the tankers /
vessel / drum / carboy samples.
9. Working on film extruders, Injection molding, Hot/ cold Press and melt flow
indexers.
10. While handling high-pressure gas sample cylinders and during their analysis to avoid
cold burn.
4.4 USE OF HOOD

Hoods should be used for any operation, which may give off flammable, poisonous vapors or
obnoxious odor. Similarly experiments. with toxic, carcinogenic and hazardous chemicals as
well as experiments generating fine dust shall be done in the fuming hood to avoid exposure /
inhalation.
1. The efficiency of the exhaust systems should be checked periodically to ensure that
adequate airflow is maintained.Do not allow materials like paper bits being sucked
into duct. It may cause choking. Air draft measurement in hood is the std. practice to
do it.
2. The concentrated acids handling, and heat related experiments (Distillation) shall be
preferably done in the fuming hood and all safety appliances shall be used during the
tests. The shutter of the hood shall be closed when fumes / vapors / dust is getting
generated during the test.
4.5 PROCEDURE FOR TAKING SAMPLES FROM PLANT

SAFETY MANUAL
DOC. NO. SM/24 Date: 01.10.2007
1. Only authorized persons of plant should be allowed to collect sample from the plants.
2. The persons collecting the sample should be fully aware about the hazard of the plant
and also properties of chemical to be collected.
3. Whenever outside person from other Departments has to collect a sample, he should
take permission from Shift-Engineer of the plant and plant operator, without
permission he should not touch any plant equipment / pipeline etc.
4. When sampling a hot or corrosive liquid, operator must wear safety equipment like
face shield / goggles, hand gloves like PVC ,Nitrile, rubber, PVC aprons etc.
5. Operator should see that sample points valves and their connections are not under
strain. Any damage to the sample point can do as much harm as bursting of pipelines
and resulting in an emergency/immediate shutdown for repair.
6. The damage to the sample line can also cause serious injuries to the operating
personnel due to sudden splashing of chemicals.
7. In case of damage to the sampling line of flammable liquids or gases there can be a
serious fire hazard also.
8. Sampling valve should be opened slowly to avoid splash and in case nothing is
coming out, close the valve immediately, inform shift-in-charge and under his
guidance try to remove the choking slowly. Do not try de-choking by keeping valve
in full open condition.
9. At the time of removing choking, try to stand away from the point and at the opposite
direction of air. Wear complete protective equipment for such jobs.
10. If sampling points become completely obstructed, the defect should be brought to the
notice of concerned Shift-Engineer.
11. Before samples are actually taken, it is necessary to purge the sampling line. When
sampling toxic or harmful gases in a confined area, collect a volume of gas sufficient
to purge the line in a sample bottle or rubber bladder and release this outside the
confined area. Sampling line must not be purged into another confined space.
12. Before taking Hydrocarbon sample ensure that no hot jobs are going on in that area.
13. For taking sample of highly toxic or poisonous chemicals, make use of gas mask or
other appropriate breathing apparatus positively.
14. Sampling containers should be placed few inches below the sample cock, so that if
any liquid flows out under pressure, it will not splash out of the container.
SAFETY MANUAL
DOC. NO. SM/24 Date: 01.10.2007
15. Always maintain safe body position during liquid sampling to avoid body contact in
case of splash.
16. When collecting samples in glass bottles, full line pressure must not come into the
bottle. For taking such samples a “Tee” branch of the Tee wide open, the other being
connected with the bottle. The open end of rubber tube should be pinched down
slowly until the sample bottle is filled at the desired rate.
17. Sample bottles or containers of different chemicals should be kept separately and
properly labeled. The sample of other chemical without thoroughly cleaning,
washing and re-labeling the bottle.
18. While collecting hydrocarbon gas samples in sample cylinder, the system has to be
earthed as they generate static charge. The care also shall extend while emptying out
the cylinder. While collecting sample stand in such a way so that the hydrocarbon
flow goes away from your body.
4.6 SAFETY IN SAMPLE BOMB HANDLING
1. Each bomb should be engraved / tagged for serial number, capacity, weight, dates of
testing etc.
2. On receipt of bomb, inspect for good condition and do leak test.
3. Sample transportation (liquid or gaseous hydrocarbon) to long distance places should
be avoided and in need should be done using suitable carrier.
4. Transportation of sample bomb without protective cap is not recommended.
5. Avoid striking a bomb against any object. They should not be thrown or dropped.
6. Check each bomb outage. Containers containing more than 80% should be vented
with proper safety precautions.
7. Visual inspection upon changing of valves and pressure testing must be done every
five years.
8. Regulators, connection gauges, other fittings used in bomb must not be used in
oxygen services.
9. After sample collection, bomb should be stored in designated place and this place
shall not have any ignition source.
10. Bombs must be kept away from any source of heat including direct sunrays.
11. Gas samples should not be drawn directly from a source under pressure. “T”
connection should be provided between source and bomb. This is primarily used to
depressurise the line between sample line valve and cylinder inlet valve.
SAFETY MANUAL
DOC. NO. SM/24 Date: 01.10.2007
12. No sooner valve on a bomb leaks, it must be turned such that valve lies in the vapour
phase. Such bomb can be vented and sent for repairs.
13. Pressure of bomb should be released slowly to avoid hazard from thermal expansion
of liquid. Bomb is to be held vertically while discharging the contents of the bomb.
14. Defective bombs should be sent for repairs after proper tagging, depressurizing and
gas freeing.
15. It is a healthy practice to use safety goggles and hand gloves while handling bombs.
16. Never leave bomb unattended after opening it.
17. When it becomes necessary to obtain higher temperature water bath below 50 deg C
should be used to warm the bomb.
18. Sample bomb should not be carried into areas, which may contain ignition source.
19. While collecting sample, stand windward side holding bomb vertically. Slowly,
open valve and hold until liquid is no longer expelled. Close valve when gas starts
coming out indicating required outage.
20. In case of disposing bomb contents, vent slowly in open space to avoid accumulation
of vapour around and ensure absence of ignition sources.
4.7 SAFETY IN EXTRUDER / INJECTION MOLDING / HYDRAULIC PRESS:

1. Proper earthing to these instruments is a must. Extruder winder /Panel board also
should be properly earthed.
2. Use exhaust fan to take away fumes generated due to polymer.
3. Safe guard for motor belts must be provided and be maintained.
4. Close Injection molding shutter door before taking out a specimen from die.
5. Ensure water circulation is made and water flow is maintained.
4.8 SAFETY IN HANDLING OF LAB INSTRUMENTS:
1. The lab instruments normally are provided with 230 volt AC supply and carries electrical
hazards and hence the supply cable shall be properly insulated and open cable / joints
shall not be kept anywhere in the cable.
2. All the instruments shall be earthed properly to avoid electrical shocks.
3. The equipments like oven / furnace shall be marked suitably (Hot) to avoid unsafe act.
SAFETY MANUAL
DOC. NO. SM/24 Date: 01.10.2007
4. The instruments which are under service / malfunctioning shall be marked as” not in use /
under maintenance “ to avoid its usage.
4.9 WASTE DISPOSAL
The waste material may contain flammable toxic or poisonous substances (solid, liquids or
gases) and adequate safety precautions must be taken for their safe disposal. Following
procedures should be adopted for safe collection, storage and disposal.
SOLID WASTE
Solid waste like Polymer Powders, Pellets etc. should be collected separately and sent to
plant to dispose it along with their polymer waste. Hazardous material should be properly
packed in watertight drums and stored at identified site with proper safety boards/instruction
and labels before transportation to hazardous waste site.
LIQUID
Hazardous liquid waste should be stored in watertight container duly labeled at an identified
location with safety boards and instructions. It should be periodically removed for safe
disposal.
GASES
These are contained in SS Bombs or bladders. Bombs should be discharged outdoor (in
open) slowly in a manner so that vapour is away from source of ignition and working area
and does not accumulate.
4.10 SAFETY IN HANDLING GAS CYLINDERS:
1 The Cylinders must be stored in cylinder room with valve end up position and chained to
prevent falling. The area should be kept clear of combustible material
2 Use needle valves to regulate the flow. Do not exchange the regulator from one type to
other type to avoid contamination.
3 For high-pressure gases, two stage gas regulators should be used when deliver pressure is
required below 5 Kg/cm2).
4 Use cylinder valve key to open / close the gas cylinder. Use two-stage pressure regulator
for control of cylinder pressure.
SAFETY MANUAL
DOC. NO. SM/24 Date: 01.10.2007
5 The line and joints shall be checked for leakage if any after changing the cylinder.
6 Always mark the cylinders “ Full / Empty ” as the case may be.
4.11 SAFETY IN HANDLING GLASS WARE:

1. Inspect the glassware for its fitness never use broken or cracked glassware or glassware
with rough edges. These are accident hazards. A star crack, or even a scratch can cause
failure under vacuum.
2. Do not use glass rod for viscous liquids or for powder settled at the bottom of the beaker
or for jelly like solution / slurry. It can lead to breakage during use and its broken edge
may cut fingers.
3. Insert glass rod / tube rounded off ends only into rubber bungs or corks.
4. Remove broken glass ware from working place and place them in the “broken Glass ware
disposal bin.”
4.12 HANDLING EMERGENCY:

1. In case of fire if it is small, try to extinguish with the available extinguisher and get help
of others to evacuate the area from other flammable materials. If fire looks
uncontrollable, immediately break the fire call point and get help of fire squad.
2. Guide the fire wing with cool mind to use proper fire fighting equipments with possible
roots to control / extinguish the fire.
3. In case of spillage use sand to cover the spillage and then dilute it appropriately and
dispose off suitably as described in lab spillage handling procedure.
4. In case of injury get the injured person out of the affected area and bring to open space.
Take decision based on the injury (e.g.: In case of chemical splash wash away the
affected portion with plenty of water and then get medical aid)
5. If any unsafe act is observed / near miss occurs. Then report it to your senior and take
corrective action.
6. In all cases inform your section head / dept. head immediately. All emergency phone nos.
shall be available and known to all working staff.
4.13 SAFETY AUDIT:

1. Each laboratory shall carry out internal housekeeping audit as per checklist
2. One monthly cross audit shall be carried out by officer, to ensure that safety systems are in
place & Safety practices are being followed.

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RELIANCE INDUSTRIES LIMITED

ALLAHABAD MANUFACTURING DIVISION

Sl.No. Description Page No.

3. SCOPE – All laboratory buildings.

4.1 General safety Rules

The following rules should be observed with regard to personal and

2. It is advisable to protect hands with barrier cream before handling solvents.

3. Hands should be washed immediately after handling chemicals.

4. Laboratory glassware must not be used for drinking water purposes.

5. Do not use compressed air to clean clothing or the skin.

4.3 EYE PROTECTION

2. Using ammonia (strong or dilute) as well as caustic solutions as eye is highly

4.4 USE OF HOOD

4.5 PROCEDURE FOR TAKING SAMPLES FROM PLANT

4.6 SAFETY IN SAMPLE BOMB HANDLING

4.7 SAFETY IN EXTRUDER / INJECTION MOLDING / HYDRAULIC PRESS:

4.9 WASTE DISPOSAL

4.10 SAFETY IN HANDLING GAS CYLINDERS:

4.11 SAFETY IN HANDLING GLASS WARE:

4.12 HANDLING EMERGENCY:

4.13 SAFETY AUDIT:

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