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September 2003
FOR RESTRICTED
CIRCULATION ONLY
OISD-GDN-211
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OISD-GDN-211
September 2003
FOR RESTRICTED
CIRCULATION ONLY
Prepared by:
FUNCTIONAL COMMITTEE ON SAFETY IN PETROLEUM LABORATORIES
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NEW DELHI – 110 001
NOTE
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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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 in Petroleum laboratories”
Oil Industry Safety Directorate
7th Floor, New Delhi House
27, Barakhamba Road,
NEW DELHI - 110 001.
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FUNCTIONAL COMMITTEE
NAME ORGANISATION
LEADER
Shri C.I. Roy Kochi Refinery Limited , Kochi
MEMBERS
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
-V-
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OISD-GDN-211 1
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1.0 INTRODUCTION: processing / handling industries viz.
refineries, gas processing plants, oil
Petroleum Testing Laboratories play a vital production/ marketing divisions as well as
role in efficient functioning of the oil/gas R&D Laboratories. It is a structured approach
industry. Tests are done in laboratory on to cover all aspects on safety of persons,
samples of various streams, collected as per property & environment within laboratory.
approved procedures, from process units/ Accordingly, it supplements the safe working
offsite. The test results are intimated to all guidelines/ practices / instructions
concerned for necessary actions. (verbal/written), which should be manualised
using these guidelines.
In the Petroleum Industry, the laboratories do
undertake various studies on catalysts & The scope of this document does not include
chemicals being used during processing and sampling procedure and description of
thereby help the management in decision- potential hazards.
making about problems related to
purchasing, processing and selling of the These guidelines are formulated primarily for
quality products as well as operational Stationery Labs. Any specific requirement for
trouble-shooting. However, at terminals or Mobile Labs may be manualised using these
depots, the laboratories are generally used guidelines.
for quality monitoring and certification of
products. 3.0 DEFINITIONS:
Petroleum Laboratory interalia, handles the
variety of oil & gas samples and uses a For the purpose of this document, the
number of chemicals and reagents in the day relevant terms are defined as under:
to day testing and certification process.
3.1 PETROLEUM LABORATORY:
This standard provides guidelines on Safety
in Petroleum Laboratories, taking into It is a place where samples of petroleum
consideration various physical, chemical and products (like feed, intermediate-products,
fire hazards in storage and handling of finished-products), samples of chemicals/
hydrocarbon samples, glassware, chemicals catalysts/ water etc, as well as those related
and reagents. Based on the guidelines of this to environment studies are tested by
standard, laboratory specific Safety manual standard methods using standard apparatus.
and Operating manual should be developed.
OISD-STD-114 on "Chemicals and their
Handling" is a related document and would 3.2 OIL / GAS PROCESSING PLANT:
provide material specific data for the various
chemicals used in Laboratory. A plant where oil/natural gas is collected and
processed to make Oil/LPG and other
In the existing laboratories, for a variety of petroleum fractions. Loading operation,
reasons, it may not be practical to comply
with some of the recommendations of this Drilling activities and facilities upstream of the
standard, like those pertaining to location & Christmas tree of a well are not covered
layout, design of workbenches, location of under this definition.
CFR Engine. These guidelines shall,
however, create awareness and help in 3.3 TOXIC:
selective implementation of the
recommendations when major modifications These substances include carcinogens,
are undertaken at existing installations. irritants or poisonous gases, liquids and
solids which are irritating to or affect the
2.0 SCOPE: health of humans.
glassware & bottle washing. It is 5.4 Floor should be resistant to fire &
preferable to segregate testing chemicals and made anti-skid. There
facilities for hydrocarbons & gases, should be no fittings on the floor that
water and effluents. CFR engine would hinder / obstruct free
room should be located in a corner. movement. Sinks and drains should
The layout on the basis of a central be made of chemically resistant
corridor or circulation aisle, with material and the drains should be
laboratory space/rooms on either properly trapped and vented.
side, is a preferred design.
5.5 Each laboratory should be provided
4.3 Microbiological section of the with efficient fume cupboards,
laboratory should be segregated and sufficiently large to permit complete
well-ventilated for maintaining enclosure of apparatus normally
hygienic conditions. used and provide with a sink for the
washing of the apparatus used for
5.0 WORK BENCHES / FUME handling toxic materials. For
Laboratories where large numbers of
CUPBOARDS digestions are to be carried out, a
separate enclosure equipped with
5.1 For good aesthetics and efficient fume cupboard may be
convenience, the workbenches provided. The cupboard should not
should be modular (equal size), be too deep to make the access
moveable and adjustable for height. difficult. The controls of the service
They should facilitate manual work connections should be provided
and support laboratory equipment. outside the cupboard. The fume
Workbenches should be fixture cupboard should have corrosion-
supported by cupboards & drawers proof fittings. It should be adequately
with room for knee space. Bench top illuminated. It is preferable to provide
should be made of material resistant a small window in the front shutter.
to fire and chemicals. Standard This facilitates easy manipulation of
bench level height is 900 mm. samples / equipment inside the fume
cupboard, without lifting the main
5.2 Standing or sitting near workbench shutter always. The cupboard should
should neither cast a shadow on the be designed such that there is strong
bench nor should one have to look upward draught even when the
up into the glare from the window. shutter is open and there is no
Workbenches should, therefore, be chance of any fumes entering the
planned always at right angles to the laboratory. This can be achieved by
window wall and lighting should be having baffle at the back. In rooms,
accordingly oriented. Sunscreen where work with extremely poisonous
shades/films should be provided to gases is done, it is advisable to have
minimise glare from windows. an air inlet at the bottom (balanced-
draught cupboard) so arranged as to
5.3 Facilities like shelves, fume cupboard sweep everything to exhaust. For
etc. should be laid as per standard fume cupboard, the exhaust fan
engineering practices to avoid over- should be able to create a free
crowding. The reagents shelves velocity of 30 meter per minute at
should be easily accessible and normal working height. Cupboard of
should not be unduly high. These highly toxic materials require higher
shelves should be provided with face velocities.
beading to prevent bottles falling off
due to vibration. The shutter pans Vapours of heavier hydrocarbons like
should be made of shatterproof / waxy gas oil, LSHS, Furnace oil
reinforced glass. samples get condensed and
deposited on the top of the fume
hood. RCR /CCR tests, involving
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"OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of the OISD
Standards/ Guidelines/ Recommended Practices."
OISD-GDN-211 4
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"OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of the OISD
Standards/ Guidelines/ Recommended Practices."
OISD-GDN-211 5
8.2 CHEMICALS & REAGENTS: 8.2.5 All experiments involving use of toxic
chemical should be carried out in
fume cupboard.
Everyone working in Laboratory should be made
aware of the adverse effects of hazardous
chemicals on potential exposure during their 8.2.6 POISONOUS SUBSTANCES:
working in the laboratory.
A separate documentation should be
available for handling poisonous
8.2.1 Based on the compatibility of substances such as cyanides. Any
chemicals, their storage must be such poisonous substances should
planned. Specific to the requirements be issued by the authorized person
in each Laboratory, periodic review to the authorized user and proper
should be done to identify inventory & record be maintained and
incompatible chemicals and a updated on each transaction.
comprehensive and updated list of
such chemicals should be The inventory of poisonous
maintained. An illustrative list of substances should be kept bare
Incompatible chemicals is given in minimum for sustaining laboratory
Annexure-I. operations.
8.2.2 Material safety data sheet (MSDS) Certain materials under normal or
provided by manufacturer of the disaster conditions can be dangerous
chemical should be extensively used to living things around them. In
as guidelines for safe storage and general, the materials which are toxic
handling of any chemical being used or can decompose into toxic
in lab. As recommended in the components due to contact with heat,
MSDS, safety appliances specific to moisture, acids or acids fumes,
the chemical should be made should be stored in a cool, well
available. ventilated place away from direct sun
light and areas of high fire hazard.
8.2.3 Each bottle/container, whether big or These materials should be
small, having chemical in it, should periodically inspected and monitored.
be properly labeled for its clear
identification with name of the The poisonous materials used for the
chemical, the concentration and the tests, should be disposed off
hazard colour code. The colour according to the procedure duly
codes for hazards should be in line approved, so as not to create
with OISD-STD-114. Such environmental hazards.
information from original container
should be transcribed on to the tags 8.2.7 WATER REACTIVE MATE-RIALS:
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"OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of the OISD
Standards/ Guidelines/ Recommended Practices."
OISD-GDN-211 6
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"OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of the OISD
Standards/ Guidelines/ Recommended Practices."
OISD-GDN-211 7
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"OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of the OISD
Standards/ Guidelines/ Recommended Practices."
OISD-GDN-211 8
Good housekeeping does much to prevent First aid should be provided to take care of
fires. Proper disposal of waste material and minor injuries, burns alongwith treatment
clean up of spillage are essential. against hazard of various chemicals used in
the Laboratory. First- aid should be
Portable extinguishers should be placed at immediately provided to the victim, even if it
convenient locations for ease of accessibility is a minor injury. After the first aid
and visibility. The running distance to locate treatment, the victim should be shifted to
an extinguisher should not exceed 15 M. nearby hospital for diagnosis/treatment giving
Atleast one portable extinguisher of each his particulars with respect to blood group etc
type should be placed, as a minimum, in
each testing / working room of laboratory. Structured training should include first-aid
Guidelines are given in OISD STD-116 & 117 against inhalation, ingestion, skin
with respect to the use of portable Fire contamination, effect on eyes, burns,
Extinguishers in laboratory. electrical shocks etc. while handling of
hazardous materials including chemicals. List
All employees should be trained in operation of persons having taken training on first-aid
of right kind of extinguisher. If a fire starts on should be displayed.
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 13.0 DISPOSAL OF SAMPLES AND
delayed alarm may cause the loss of CHEMICALS:
precious minute and allow a fire to grow.
A waste disposal scheme should be
After extinguishing the fire, it should be developed for safe disposal and incorporated
notified to the Fire & Safety for replacement in the laboratory operating manual. Waste
of any used fire extinguishers. materials generated in a laboratory can be
broadly classified as ‘Solid Wastes’ and
Heat / smoke detectors should be provided in ‘Liquid Wastes’. While the leftover gas
the Laboratory as per need. Output of the samples like fuel gas should be discharged
detectors should be connected to the to safe height through the fume hood.
audio/visual Alarm system of the fire station/
Main Control Room. 13.1SOLID WASTES:
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"OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of the OISD
Standards/ Guidelines/ Recommended Practices."
OISD-GDN-211 9
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"OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of the OISD
Standards/ Guidelines/ Recommended Practices."
OISD-GDN-211 10
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"OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of the OISD
Standards/ Guidelines/ Recommended Practices."
OISD-GDN-211 11
soaked with oil or chemical and & Don’ts, First-aid chart, use of PPEs, use of
affected part of the body should be various types of Fire Extinguishers,
flushed with water. Organogram of Disaster Management along-
with Telephone numbers, Roles &
18.3 Skin contact or inhalation of harmful Responsibilities of the personnel during
substances should be avoided. emergency etc..
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"OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of the OISD
Standards/ Guidelines/ Recommended Practices."
OISD-GDN-211 12
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"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
16 Hand book of Laboratory Safety, 3rd Edition, Editor: A Keithfurr, CRC Press, 1990.
Annexure-I
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"OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use
of the OISD Standards/ Guidelines/ Recommended Practices."
OISD-GDN-211 15
25) Sodium perborate 26) Sodium per chlorate 27) Sodium per sulphate
28) Strontium chlorate 29) Strontium Nitrate 30) Strontium Nitrite
31) Thorium Nitrite 32) Thorium Nitrate 33) Zinc chlorate
34) Zinc peroxide 35) Phosphorus
pentoxide
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 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 Nitric acid and Hydrogen peroxide.
Aniline
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,
sodium carbides, powdered metals.
Copper salts Acetylene, Hydrogen peroxide.
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"OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use
of the OISD Standards/ Guidelines/ Recommended Practices."
OISD-GDN-211 16
Cyanides Acids
Ethylene Greater than 3% with methylene chloride (explosive)
diamine
Flammable Ammonium Nitrate, Chromic Acid, hydrogen peroxide, Halogens, Nitric Acid, sodium
Liquids peroxide.
Hydrocarbons Halogens, Chromic Acid, peroxide.
Hydrogen Copper, chromium, irons most metals and their salts, flammable fluids, aniline, Nitro
peroxide methane.
Hydrogen Nitric Acid and Oxidizing gases
Sulphide
Iodine Acetylene, Ammonia
Mercury Acetylene, Hydrogen
Methylene Greater than 3% Ethylene diamine (Explosive)
Chloride
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 Water
pentoxide
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.
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"OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use
of the OISD Standards/ Guidelines/ Recommended Practices."