KOC.ge.031 - Laboratory Safety and Hygiene Procedure

KOC.GE.031 – KOC.GE.031 – Laboratory Laboratory Safety and Hygiene Procedure Page 1 of 22

LABORATORY SAFETY AND HYGIENE PROCEDURE Document Number: KOC.GE.031 Number: KOC.GE.031 Document Author:

Document Coordinator:

Team Leader Health & Environment

Team Leader Standards

Approved by:

KOC HSEMS Procedures Sub-committee

Authorized by:

KOC HSSE Implementation Implementation Committee

Original Issue Date:

May 15th, 2011

Document Control Tier:

Tier 3

February 04, 2015

Next Review Date:

February 03, 2018

Revision/Review Date:

1.0. Purpose/Scope The laboratory in the upstream oil & gas sector has distinctive functions of testing and analysis facilities for routine operational requirement as well as product quality assurance. Although laboratories are considered less hazardous than oil and gas facilities, there are potential hazards associated with laboratories activities, such as high temperature, handling chemicals, chemicals, usage of glassware, etc. Laboratories incidents can be minimized by understanding the hazards involved and by putting this knowledge into practice. The purpose of this document is to provide guidance and outline responsibilities for all the laboratories that involves handling and testing of crude oil, hydrocarbons, water and other production related samples in KOC Facilities and it does not applicable for the Laboratories (like pathological / microbiological / radiological and Others) that are being operated in Ahmadi Hospital. This procedure provides the guidance and outlines responsibilities for all aspects associated with: 

General Safety Safety Precautions Precautions

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Lab safety safety requirements requirements

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Safe Work Practice (SWP)

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Standard Operating Operating Procedure Procedure (SOP)

Housekeeping

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Health & hygiene

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Use of Engineering Controls & PPEs

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Safety in sampling, handling & Storage of of chemicals in the Lab

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Hazardous Waste Management & disposal

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Emergency Management

2.0. Definitions Authorized / Competent Electrical Person: Person: An electrical person, who has been authorized in writing by the respective area Snr. Electrical Engineer, to work / isolate / de-isolate (energize / de – energize) a high & / or low voltage electrical equipment. (For details please refer Permit to Work Procedure (Document (Document Number: KOC.SA.004)

Control Tier 3

Revision Date: February. 04, 2015 Uncontrolled Copy if Printed

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Designated Area: An area which may be used for work with carcinogen materials, reproductive toxins or substances which have a high degree of acute toxicity, a designated area may be the entire laboratory, an area of a laboratory work work station, or a device such as a laboratory hood. Face velocity - Average velocity of air moving perpendicular perpendicular to the hood face, usually expressed in feet per minute (fpm) or meter per second (m/s) (As per ANSI/ASHRAE 110, 1995). Hazard: A Hazard: A state or condition or physical or chemical or biological characteristic is having the potential for causing damage to property, environment and health of people. The following are the hazards that are associated with the activities / operations in the laboratories: laboratories: 

Handling Handling of Toxins that may affect the Liver, Kidney Kidney or Nervous Nervous System

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Handling Handling of of Irritants, Irritants, Corrosive Corrosive or Sensitizers Sensitizers

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Handling of agents agents that act on blood system or damage the Lungs, Skin, Eyes Eyes or Mucous membranes

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Fire/Explosion

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Trip and Fall

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Flooding

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Asphyxiation

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Electric shock

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Personal injury

Hazardous Chemical & Reagents: Means a chemical and reagents for which there is statistically significant evidence based on at least one study conducted in accordance with established scientific principle that acute or chronic health effects may occur in exposed Laboratory employees. Hood Face - The plane of minimum area at the front portion of a laboratory fume hood through which air enters when the sash/es is/are fully opened, usually in the same plane as t he sash/es when sash/es is/are present (As per ANSI/ASHRAE ANSI/ASHRAE 110, 1995). Laboratory: A Laboratory: A laboratory is a place equipped for experimental study in a science or for testing and analysis of the samples. Laboratory Fume Hood or Fume Hood: a box-like structure enclosing a source of potential air contamination, with one open or partially open side, into which air is moved for the purpose of containing and exhausting air contaminants, generally used for bench-scale laboratory operation but not necessarily involving the use of a bench or a table (As per ANSI/ASHRAE 110, 1995). Safety Data Sheet (SDS): Safety Data Sheet (SDS) provides comprehensive information for use in workplace chemical management. Employers and workers use the SDS as sources of information about hazards and to obtain advice on safety precautions. The SDS is product related and, usually, is not able to provide information that is specific for any given workplace where the product may be used. However, the SDS information enables the employer to develop an active program of worker protection measures, including including training, which is specific to the individual workplace and to consider any measures that may be necessary to protect the environment. Information in a SDS also provides a source of information for other target audiences such as those involved with the transport of dangerous goods, emergency












3.0 General Requirements 

KOC HSEMS Element 5, Operations and Maintenance

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KOC HSEMS Element 3, Risk Assessment, Compliance and Management Management

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Chapter II (The work environment and the indoor environment), Appendix no: 2, (Section 1-1, Clause 6), Appendix no: 3-1 (Maximum Limits Allowance for Occupational Exposure to Chemical Substances), Appendix no: 3-2 (Maximum Limits Allowance for Biological Effect As a Result of Occupational Exposure to Chemical Substances), Appendix Appendix no: 333 (Table of Standard Guidelines for Chemical Substances in Indoor Environment), Law 16/1996 as amended amended – – Kuwait Kuwait Environment Public Authority Regulations. Regulations.

4.0. Key Responsibilities: 4.1. Team Leaders (Water Handling Team / EO Team) 

Shall be responsible for overall administrative control of Laboratory Laboratory functions.

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Shall support & approve all the logistic requirements of the laboratory in order to ensure smooth functioning of laboratory activities.

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Shall ensure that the requirements requirement s of this HSEMS Procedure are implemented

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Shall ensure all desired requirements requirement s for safety & hygiene of the laboratory personnel.

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Shall be responsible for ensuring that emergency evacuation procedure is available for the laboratory facilities and evacuation/emergency drills are carried out at least annually within the Lab-building.

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Responsible to develop Health surveillance program of individuals exposed to hazardous chemicals and reagents at stipulated frequency (As Per SDS).

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Shall ensure that risk risk related to laboratory activities activities / areas are identified identified in the environment, environment, safety and health risk registers.

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Shall ensure ensure that updated and approved approved Safety & Health Health Risk, Environmenta Environmentall Aspect and HSE Compliance registers are available for the laborat ory facilities and personnel.

4.2. Chief Chemist 

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Shall ensure availability of updated Lab manual which comprises written SOPs (Standard Operating Procedures), Safe Work Practice (SWP) and Work Instructions for all laboratory related tasks involving testing / analysis analysis / sample preparation. preparation. Shall ensure the compliance to all HSE requirements as per HSEMS Procedures. Procedure s. Shall maintain a current, accurate chemical and reagents inventory by identity, location, and quantity. Shall obtain, use, and make available a safety data sheet (SDS) issued within 3 years for all chemicals and reagents being handled within laboratory. Shall ensure the laboratory building is equipped with with all required & suitable Safety & Fire protection arrangements including the detection system (if required) and chemical spill kit. Shall approve all new laboratory testing procedures & ensure proper adherence of












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Shall ensure training employees to recognize, control, and avoid chemical hazards for each chemical and reagents. Shall ensure persons trained in B. A. (Breathing Apparatus) are available in shift. Shall ensure that all the Safety Equipment available in the laboratory are in working working order, updated and Calibrated as per the Manufacture recommendation. recommendation. Shall ensure training and competency of all Lab Technicians on “Hazards Communications Program” prior to practising in the lab to recognize, control, and avoid chemical hazards for each chemical and reagent. Shall approve approve the quality quality and safety of of chemicals chemicals to be used used in the laboratory laboratory

4.3. Production Chemist / Senior Lab Technician 

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Shall assist Chief Chemist to ensure availability of Lab manual which comprises updated Standard Operating Procedures for all laboratory analysis. Shall ensure proper handling of the crude, gas and storage of laboratory and field chemicals and reagents.

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Shall ensure safe disposal of waste waste as per KOC rules and regulations

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Shall ensure periodic review of procedures and update as and when required

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Shall ensure the periodic periodic maintenance/testing/cali maintenance/testing/calibrations brations of all Laboratory Laboratory equipment & appliances as per requirements. Provide proper technical advice/ assistance assistanc e to Chief Chemist as and when required. Shall ensure availability availability and serviceability serviceability of Safety Showers, Eye Wash Fountains, Fountains, Fume Hoods, PPE and Anti-Spill Kit/Material Adheres to HSE HSE rules and regulations and advise subordinates

4.4. Laboratory Technician-1 

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Shall assist Production Chemist to ensure proper handling and storage of laboratory and field chemicals and reagents. Shall be responsible responsible for ensuring ensuring the implementation implementation of the procedure following the established methods and quality requirements procedures on a day to day basis in the shifts. Shall support & guide other Lab-Technician-II Lab-Technici an-II in order to perform their activities properly with safety. Shall follow follow instructions instructions of Chief Chief Chemist / Production Production Chemist Chemist on day-to-day basis. Shall test the performance of of Fume Hoods on a daily basis at the beginning of each shift. Strictly follows company’s new HSEMS procedures, records on laboratory chemical wastes and efficiently manages their disposal

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Maintaining operating equipment, fume hoods in safe operating condition

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Enforce proper use of PPE as per HSEMS procedure. procedure .












4.5. Laboratory Technician-2 

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Shall adhere to the instruction instructi on given by the superior related to proper handling and storage of crude, gas and laboratory and field chemicals and reagents Shall be responsible for ensuring the implementation implementatio n of the procedure on a day to day basis in the shifts. Shall follow the sampling and testing standard methods on day-to-day day-to- day basis. Shall wear the desired PPE when handling the crude, gas and field chemicals& reagents

4.6. Fire Teams (N & WK / S & EK / Support Services) 

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Shall review and advise the adequate quantities quantitie s of suitable Fire Extinguishers. Extinguishers . The area owner will arrange for the fire extinguishers. Shall review review and advise advise the adequate quantities of fire blankets. The area owner will arrange the fire blankets. Shall arrange arrange training training to laboratory staff regarding regarding use of Fire Extinguishers Extinguishers & Fire Fire Blankets on request of the concerned team.

4.7. Team Leader - Directorate / Asset HSE Team 

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Asset HSE Team shall be responsible to carry out periodical inspection of laboratory and advise the asset owner for corrective measures in case any deviation is observed. Shall assist in providing general HSEMS awareness awarenes s amongst KOC / Contractor’s laboratory personnel. personnel. HSE Team should review and advise on PPE and new chemicals & reagents before introducing them. And Chief Chemist must provide updated SDS of lab chemicals within 3 years Shall monitor indoor air quality within within the laboratory during Routine HSE Inspections Inspectio ns and on request of Controlling Team Leaders. Shall carry out personnel sampling and Biological Monitoring based on Chemical Inventory & SDS. HSE Team Advise and ensuring the implementation of the required Biological test based on SDS and the concerned team has to arrange to provide these test in liaising with HR & Ahmadi hospital in addition to Providing data to HSE Team. Shall provide provide suitable suitable HSE advice (on request of the user user team) about the new chemicals and reagents to be introduced / used in laboratory. Recommended PPE must be sought from the SDS supplied with those chemicals and reagents. However the Chief Chemist must ensure the availability of Safety Data Sheet (SDS) of all chemicals and reagents being used in laboratory.












5.0 Laboratory Safety & Hygiene Procedure: 5.1. General Safety Precautions (a) As per KOC.L.028 Rev 4, Clause 7.2.9, Laboratory shall not be located inside the Control Building. It should be located separately in a safe and non-hazardous Area/Zone. (b) All the tests and experiments must be carried out by following the safe safe methods as laid down in standard operating operatin g procedure or as directed. No test or experiment outside the scope of approved laboratory facilities and procedures or without permission of Supervisor is permitted. (c) Before leaving work, ensure all lab work station are clean and tidy and all appliances and equipment not required to be used, are properly turned off, disconnected or otherwise rendered safe; particularly electrical / gas equipment. KOC HSEMS procedure for Housekeeping KOC.GE.034 shall be referred for guidance and proper implementation. (d) Never distract attention of other employees unnecessarily. Employees should give their fullest attention to their job at all times to prevent accident and mistakes (e) Gas Burners should not be used inside laboratories, which are handling flammable chemicals such as Methanol, Butanol or Xylene (preferably use Heating Mantels, Hot plates or Water baths) (f)

Ensure that the chemical chemical reaction reaction controlled controlled and does not create create any risk to personnel, personnel, equipment, work area, etc.,

(g) Chemical Hygiene Plan for the Laboratory shall be prepared and followed. (h) Sample bottles should should be carried carried in the carriers carriers or on sample trolleys trolleys (i)

Test requiring use of open flame in laboratory shall be restricted restrict ed and allowed only in designated locations.

(j)

Use proper Personal Protective Equipment PPE (gloves, apron, safety glasses / goggles and face shield, safety shoes as instructed by the relevant SDS, while handling flammable, reactive, corrosive or toxic chemicals to avoid injuries, wearing jewelry is not recommended in the laboratory). A dedicated PPE cabinet at a suitable place shall be installed to keep, maintain inventory & proper maintenance of all the PPEs in ready to use condition.

(k) When drawing drawing samples of of toxic or corrosive products products use proper protective equipment. equipment. (l)

All water samples at the EWDP’s/water treatment and injection shall be collected by the lab technician’s (either KOC or KOC or Contractor) and all other samples (Crude and Gas) shall be drawn by respective production operations or Gas Operations teams for the purpose of analysis. No Laborers shall be involved in the processes of sampling or preparation.

(m) All containers of chemicals and samples should be labeled clearly and correctly. All unlabeled materials should be discarded under the direct supervision of a Supervisor/ Chemist. and dealt as unknown hazardous chemical substance (n) Liquefied hydrocarbon hydrocarbon samples must not be stored stored in glassware. glassware. (o) The floor in the Lab shall be graded towards drain point and flooring shall be of nonskid type. (p) Draw samples slowly and cautiously, particularl particularly y the samples with high temperature and pressure.














(r)

Cork borer shall be kept sharp 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.

(s) Before inserting glass tube into stopper hole, moisten the hole and the tube with water or glycerin. Hold the stopper firmly with with the thumb and forefinger and gradually gradually push it by rotating the tube, holding with thick cotton cloth. (t)

Air pressurizing system in the laboratory should be kept operative to maintain positive air pressure within within the room. This will prevent prevent entry of flammable gases from outside. outside.

(u) All laboratory personnel personnel must be familiar familiar with location location and the use of fire extinguishers, extinguishers, safety showers, eye wash fountains, fire blankets, gas masks and chemical spill kit. (v) When using compressed air for cleaning/drying cleaning/d rying glassware, slowly open the air valve. Excess pressure can cause hazard. (w) When new or unfamiliar chemicals and reagents are encountered refer to its recent SDS, to determine their hazards before before handling them. In case, it cannot be determined, treat them as toxic or otherwise hazardous material and dispose the chemical or reagent safely as per KOC procedures (x) Perform the chemical reactions under a ventilated hood if harmful fumes or aerosols may be generated. (y) Perform all procedures involving hydrofluoric hydrofluor ic acid (HF), strong mineral acids, bases, flammable and reactive chemicals under a ventilated hood (and with proper PPE). (z) Obtain laboratory supervisor approval before working with any carcinogenic compounds in laboratory. (aa) Don’t store or stack incompatible chemicals or reagents in close proximity to each other (refer back to SDS). (bb) Laboratory identification board shall be installed at the entrance/exit doors. Approved Emergency exit routes with floor details & assembly points shall be displayed at prominent places in the laboratory for quick and safe evacuation. (cc) Smoking in the Lab offices and Laboratory is strictly prohibited. (dd) Stored items or equipment equipment should not block access to the fire f ire extinguisher(s), safety equipment, or other emergency items. (ee) No running or horseplay in laboratory areas shall be permitted. (ff) Avoid draining of chemicals into the common drainage system. Only those chemicals should be drained to sewer systems which do not have adverse impact on marine environment. (gg) After analysis, used/ left over samples e.g., Hydrocarbon should be drained to oily water sewerage only.












c)

The laboratory flooring shall be made from a non skid & non – reactive – reactive type material, which shall be kept free from oil, grease, chemicals, water or any slippery substance splashed over it. The work top should also be chemical resistant material. The fire extinguishers and other safety appliance inside the laboratory shall be regularly inspected and kept in ready to use condition.

d)

The chemical chemical reagents reagents toxic toxic and non-toxic, test equipment, equipment, partially partially used samples etc. etc. should be returned to the designated storage immediately immediately after use.

e)

Reagents and equipment items should be returned to their proper place after use. This also applied to samples in progress. Contaminated or dirty glassware should be placed in specific cleaning areas and not allowed to accumulate.

f)

Any spills should be immediately cleaned with a suitable solvent, covered with absorbent granules and neutralized safely prior to disposing off as per KOC Chemical spill cleanup procedure (KOC. EV 005) procedure.

g)

Only approved approved Chemicals Chemicals Anti-spill Anti-spill pads pads are to be used for cleaning cleaning up, used used Anti-spill pads/ sheets should be placed special plastic bags with “Hazardous Waste Label” and strips to close them, they shall be kept in covered metal receptacles.

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These receptacles must be emptied out or removed from the laboratory at suitable periodical intervals, preferably daily basis.

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The waste materials must be disposed off by a safe & environmental environmenta l friendly procedure to prevent any air, water or ground pollution. (As mentioned in clause 5.6-waste disposal.

j)

It is recommended recommended to keep adequate numbers of suitable waste-skips or bins to segregate different categories of wastes and dispose accordingly. The broken glass must not be put in t he same container as that for waste paper or rags.

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The waste skip/bin, which has contained flammable material, must be thoroughly washed prior to its reuse.

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It is also advisable to take special care while draining or disposing off the liquid liquid waste. waste.

m) If the sink or drainage system is not not purposely designed to accept spent acids or alkaline solution then arrangements must be made to keep such waste liquids into a separate receptacle for safe neutralization neutralization and careful disposal. n)

The drain system must be regularly checked to prevent any blockage and the wash downs are properly routed.

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All highly flammable liquids liquids must be kept kept in a special special Flammables Flammables Storage Cabinet, Cabinet, marked with the appropriate safety signs. The potentially dangerous substances such as corrosive, reactive and flammable materials must not be stored inside the same storage cabinet.












B. Chemical and Reagents Identification & Labelling: a)

All sample bottles, packages and containers of chemicals & other hazardous materials must be clearly marked and labelled for easy identification. The labelling can be done in compliance with an international protocol The Globally Harmonized System of Classification and Labelling of Chemicals (GHS).

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Use only authorized chemicals and reagents required required for a particular process. Do not substitute.

c)

Identify Identif y the chemical and reagents before use. Refer to the SDS, SDS , review and understand hazards and OEL‘s / OEL‘s /PEL’s PEL’s before using chemicals or reagents.

d)

The containers, containers, bottles or packages packages without without labels labels and containing unidentified material must be dealt as a hazardous waste and disposed off safely under the supervision of a Laboratory Technician or chemist.

e)

An appropriate appropriat e warning notice/s shall be prominently posted near the laboratory to alert the people about the potential hazard & associated associated risks due to t o chemical handling.

f)

The first aid instruction instructio n (for any incident such as electric shock, severe burn) and standard preventive measures must be displayed prominently inside the laboratory for immediate response. (as per SDS)

g)

The Safety Data Sheet (SDS) of all laboratory chemicals / reagents including Xylene, Methanol, Butanol & Lotoxane etc. should be readily available for ready reference.

h)

Chemicals and reagents should be segregated and stored by hazard classification and compatibility.

i)

The following hazard classifications can be used used as a guide for segregating segregating chemicals. Storage Compatibility: Compatibility: Compressed Gases Water Reactives Organic Peroxides and Peroxide forming materials Oxidizer Flammable Corrosives Toxins- - carcinogens etc. Genera Chemical Special Hazardous Materials: Radioactive etc.

5.3. Health & hygiene: A. General:












e) Eating, drinking, drinking, smoking, storing of food, personal personal belongings, belongings, or utensils, applying applying cosmetics, and inserting or removing contact lenses are not permitted in laboratory area;. f)

Always wash your hands with suitable detergent immediately after handling the chemicals and before leaving laboratory. Also remove gloves before answering the telephone or opening doors to prevent the spread of contamination.

g) Do not use any of the laboratory containers for drinking water or storing any other materials such as personal items. Or drink from beakers or other laboratory containers (glassware). h) Never pipette by by mouth. mouth. Always use a bulb to pipette. pipette. i)

Never taste Chemical substance and reagents for Identification. Identific ation. Never directly smell the source of any chemical vapor.

j)

Contact lenses are not allowed allowed during work in the lab. Even when worn under under safety goggles, various fumes may accumulate under the lens and cause serious injuries or blindness.

k) Special Safety Safety gloves and and masks should should be worn worn before handling solvents. l)

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

m) Open wounds, cuts, scratches and grazes should be covered with waterproof dressings. n) Appropriate Appropriat e shoes must be worn. worn. No sandals, thongs, open toed or open heeled shoes. Roll up sleeves and tie up loose clothing and long hair when working with equipment, open flame, any chemicals or biological substances. B. Ventilation: a) Normally the laboratory laboratory shall be provided provided with an efficient ventilation ventilation & fume / vapour vapour extraction system to ensure adequate air circulation. b) In case the operation involves involves generation generation of flammable flammable / toxic vapour vapour (as in case of crude oil laboratory). Explosion Proof fume cupboards equipped with air filtration system should be used to protect the outer environment. c) The fume cupboard shall be regularly checked for efficient extraction of vapours and crude oil laboratory shall be equipped with detection system to monitor flammable & toxic vapours. When not in use, the sash of the hood should be kept closed and the work should be performed as deeply within the fume hood as possible. d) The air-conditioning air-conditionin g system in the crude oil laboratory will be 100% fresh air supply to












recommend precautionary measures to control the risk before the job is performed. (Refer.KOC.SA.024) b) Laboratory personnel shall wear safety boots or special laboratory safety shoes. They shall not wear sandals, open – open – toed toed shoes or slippers. c) Laboratory personnel personn el shall always wear lab coat. The primary purpose of a lab coat is is to protect against splashes and spills. A lab coat should be nonflammable, where necessary, and should have snap fasteners rather than buttons so that they can be readily removed. These coats are to be fastened closed while working and removed prior to exist from the laboratory. Long legged long sleeved clothing shall be worn underneath. d) The appropriate respiratory respiratory protection shall be provided provided whenever working in toxic environment. Validity of using the mask will depend on the manufacture’s recommendations. e) Laboratory employees shall wear appropriate hand gloves. If the gloves become contaminated they should be removed and discarded as soon as possible. Neoprene is good for protection against most common oils, aliphatic hydrocarbons and certain other solvents. Also for concentrated acids and alkalis, and organic solvents, natural rubber, neoprene or nitrile gloves are recommended. f)

Check gloves gloves for cracks, cracks, tears, tears, and holes. holes. If direct direct chemical chemical contact occurs, replace replace gloves regularly throughout the day.

g) The appropriate respiratory protection shall be provided whenever working in hazardous environment. h) Atmosphere Atmospher e or the work nature may cause inhalation of harmful substances. Such equipment shall be kept in ready to use and hygienic conditions. i)

The personnel shall be trained to wear respiratory respirat ory equipment.

j)

Use of H2S detector detector while removing removing crude oil from from crude oil sampling sampling bottles bottles

k) Develop Health surveillance program of individuals exposed to hazardous chemicals at stipulated frequency (As Per SDS) B. Eye Protection: All laboratory laboratory personnel personnel should should use safety safety goggles with said shield (appropriate for chemicals and reagents handling) while doing following jobs; a) Working with any glass apparatus maintained under positive pressure or under negative pressure such as vacuum distillation etc.














f)

Working with with perchloric acid acid or its salts. It It should be remembered remembered that certain commercial drying agents are salts of perchloric acid. Perchloric acid or perchlorates will explode on contact with organic matter.

g) Working with with strong alkalies alkalies and acids acids either solid solid or in in solution. h) Exposed to danger of chemical splashing. C. First-aid: a) All the first aid facilities including Emergency Safety Shower (ESS) and Eye Wash Stations must be available and functional in a ready to use condition. Laboratory staff working in that area must be familiar with the operation and utility of this emergency facility. b) It is required to train the Laboratory Laboratory Staff to deal with First Aid cases in case of emergency (Ref Doc. No. KOC.HE.004 - “Occupational Health, Hygiene - First Aid”) c) In case of chemical chemical and reagent reagent contact, the affected part part of the body body (e.g. eyes, eyes, face, and body) must be thoroughly flushed with clean water for 15 minutes and in case of eyes, should be washed with clean potable water for 15 minutes as well. Medical assistance should be obtained as necessary. d) Any exposure to toxic chemicals chemicals and reagents through through inhalation, inhalation, skin absorption or or ingestion shall require immediate medical attention and specialized specialized medical treatment at hospital (call (call 160 for 160 for any emergency case) e) First aid box and rescue equipment equipment must be available available and accessible accessible in case of emergency. f)

The first aid aid instructions instructions for any untoward untoward incidents incidents such as electric electric shock, severe burns burns and standard preventive measures must be displayed prominently inside the laboratory for immediate response.

g)

Ensure availability of appropriate “Antidote” for chemical under guidance from Ahmadi












B. Use of Fume Hood: a) Work that involves hazardous and/or noxious materials which are toxic, odoriferous, volatile or harmful shall be conducted within the Fume Hood b) The efficiency of of the exhaust systems should should be checked periodically periodically on a daily basis to ensure that adequate air flow is maintained. c) Do not allow materials materials like paper paper bits being sucked sucked into duct. It may cause choking. d) Fume Hood ventilation systems should have an airflow face velocity of not less than 0.5 m/sec (linear) and not more than 1 m/sec across the face of the hood. e) According to the standard standard ANSI/ASHRAE ANSI/ASHRAE 110-1995, 110-1995, Method of Testing Testing Performance Performance of Laboratory Fume Hoods (1995), airflow face velocity shall be periodically tested with a Certified air flow meter. Specifications of air flow meter is provided in Appendix 1 for further reference and usage. f)

All samples, chemical reagents and other chemicals emitting fumes or gases should be kept at least 15 cm from cm from the edge of the Fume Hood work plate, to ensure the proper containment of those fumes within the fume hood otherwise they might get out the fume hood into the laboratory laboratory itself.

g) Blocking or disturbing the steady flow of air inside the Fume Hood by any big obstacle (e.g. Big Chemical Container/ drum, Water Bath, Oven, etc.) is forbidden. h) Avoid creation of strong cross drafts more than 1 m/sec caused by open doors and windows, air blowers, air conditioning and/or heating vents, or personnel movement. Drafts will pull contaminants from the hood into the laboratory i)

Over a period of time “peroxides” can form in the hoods and ducts. To avoid peroxide peroxide hazard in hoods and ducts, it should be water washed periodically (record of such cleaning should be maintained).

C. Procedure for taking samples from Facilities:












j)

Sampling containers should be placed placed few inches below the sample sample cock, so that if any liquid flows out under pressure, it will n ot splash out of the container.

k) When collecting samples in glass glass bottles, full line line pressure must must not come into the bottle. For taking such samples a “Tee” branch of the Tee wide open, the other being connected connecte d with the bottle. The open end of rubber tube should be pinched down slowly until the sample bottle is filled at the desired rate. l)

Sample bottles or containers containers of different different chemicals chemicals should be kept separately separately and properly labeled. According to ASTM Method D 4057 (Manual Sampling of Petroleum and Petroleum Products), the sample containers must be selected and used based on the characteristics of the sample, as per the below provided table. Type of Sample

Sample Container

Sweet and Sour Dry / Wet Crude

Glass Container

Brackish Water

Plastic or Glass Container Container

Produced Water

Plastic or Glass Container

Oily Water

Glass Container

Effluent Water

Glass Container

Treated Sea Water

Plastic or Glass Container

m) In case of a sample cooler, it should be ensured that the cooling water of the sample cooler is in commission prior to withdrawing withdrawing the samples. D. Safety in gas sample jar / bottle handling:












l)

Pressure of Sample jar should be released slowly through dip tube to avoid hazard from thermal expansion of liquid. Sample jar is to be held vertically verticall y keeping dip tube end up.

m) Defective Sample jars should be sent for repairs after proper tagging, depressurizing and gas freeing. n) It is a healthy practice to use safety goggles goggles and hand gloves while while handling Sample Sample jars. o) Never leave Sample jar unattended unattend ed after opening it. p)

When it becomes necessary to obtain higher temperature temperatur e water bath below 50 should be used.

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q) Sample jar should should not be carried carried into areas which which may contain ignition ignition source. source. r)

While collecting sample, stand upwind side holding Sample jar vertically. Slowly, open valve and hold until liquid is no longer expelled. Close valve when gas starts coming out indicating required outage.

s)

In case of disposing Sample jar contents, vent slowly in open space to avoid accumulation of vapour around and ensure absence of ignition sources.

E. Compressed Gas Cylinders: The cylinder of compressed gas can pose a chemical as well as physical hazard. a) If certain gas is being being used regularly, regularly, it is recommended recommended to install a permanent permanent manifold manifold and gas supply arrangement with cylinders secured outside the laboratory. b) Gas cylinders cylinders must be stored stored away from flammable flammable and heat heat sources. c) Gas cylinders must be be fixed in a manner manner that prevent prevent fall of the same on the the ground or it must be placed in rooms allocated for this purpose. d) Cylinders must be stored in a vertical way and be tied with chains. It is completely prohibited to roll cylinder horizontally on earth. They must be transported in special cars












n) Under no circumstance circumstance attempt be made made to mix gases in in cylinders or transfer transfer gas from one cylinder to other. o) The pressure regulator, regulator, valves, relief device, device, connections and hose lines lines should be regularly inspected for any damage. p) The cylinders must be secured in an upright position in purpose made rack duly chained or strapped to a wall or other fixed support. q) A cylinder should be transported through a purpose built trolley or handcart with safety cap on and strapped for security. r)

The empty cylinders shall be marked and stored separately in the designated rack outside the laboratory. Cylinder valves shall be kept protected by the protective cap.

s) It is highly recommended recommended to install install a multi-gas detection detection and alarm alarm system to alert alert in case of any gas leak. t)

The main valve on a cylinder must be kept closed whenever the cylinder is not in use.

u) An appropriate pressure regulator must be used and the regulator should not be modified to fit to fit a cylinder it was not designed for. v) Oil or grease shall never be used to lubricate valves / fittings on oxygen or oxidizing Gas cylinder, because a fire or explosion can result. w) Empty or damaged gas cylinders in addition addition to cartridges, sterilization containers containers and aerosols should be dealt as hazardous waste x) The standard color coding of the pressurized shall be adhered to. F. Electrical Equipment: a) All electrical equipment inside the laboratory must be installed and serviced by an authorized / competent electrical person. b) All electrical fittings in the the Lab shall be as per Hazardous Hazardous Area Classification Classification of the














d) A purposely made baskets baskets and trolleys shall shall be used for the transporting transporting bottles and large containers. e) The windows for glass enclosures should be made of laminated or wired glass to ensure maximum protection to sustain exothermic reaction or any abnormal pressure build-up. H. Fire Protection: a) The laboratory shall shall be equipped equipped with suitable suitable detectors for fire & toxic gas detection. detection. b) The adequate numbers numbers & type of of fire extinguishers extinguishers duly approved approved by Fire Team shall shall be made available in the laboratory for emergency use. c) The fire blankets of the type duly approved by Fire Team will also be kept at easily accessible range from working bench. a) The laboratory staff staff shall be trained trained in use of Fire Extinguishers Extinguishers & Fire Fire blankets. 5.6. Waste disposal: It is essential on the part of the user of chemicals to follow the established procedure concerning proper disposal of hazardous waste and minimizing its generation. The waste material may contain flammable toxic or poisonous substances (solid, liquids or












C. Gaseous waste: a) Sample cylinders / jars 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. accumulate. 5.7. Emergency Management: In view of the nature of occupancy & type of laboratory analysis being carried out involving hydrocarbons, the Laboratory poses a high potential for Fire & Explosion incidents with severe consequences. Hence utmost attention needs to be paid all the time for the preventive measures. Emergency Evacuation Evacuation routes and Emergency Exit doors shall be identified for the Laboratory and marked appropriately. Emergency exit doors shall be of push bar type and have illuminated sign for easy identification. Approved Emergency exit routes with floor details & assembly points shall be displayed at prominent places (entrance and exit doors) as specified above in the Clause (y) of Section 5.1. However, for all types of emergencies, ERAP (Emergency Response Action Plan) prepared for the Lab shall be followed. It is very important that all personnel must aware of the emergency plan within their own building and know what their role is during any emergency. In order to help in the training of












6.0. Key Documents/Tools/References 

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ASTM Method D 4057 - Manual Sampling of Petroleum and Petroleum Products U.S OSHA standard 29 CFR 1910.1450 for Occupational Occupatio nal Exposure to Hazardous Chemicals in Laboratories A Guide to The Globally Harmonized System of Classification Classificat ion and Labelling of of Chemicals (GHS) ANSI/ASHRAE 110-1995 - Method of Testing Performance of Laboratory Fume Hoods (1995) ANSI/AIHA/ASSE Z9.5-2012 - American American National Standard for Laboratory Laboratory Ventilation. Hazard Communication Standard (HCS) , Occupational Safety & Health Administration Administration (OSHA)

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KPC Document - OH.KPC.40.04.1 “Chemical Hazard Communications”

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KPC Document - OH.KPC.037.04.1 “Indoor Air Quality Management” Management”

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KPC Document - EV.KPC.019.04.1 “Chemical Handling”

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HSEMS Procedure “Chemical Hazard Management and Communication Procedure”












REVIEW & REVISION LOG Review/ Revision Date

Revision Details

8th August 2010

Draft procedure circulated among HSEMS Implementation Committee members for review & comments

13th September 2011

Final procedure approved by HSEMS Implementation Committee and issued for implementation implementation

04th February 2015

Clause 1.0: Scope / Purpose was amended and updated. Clause 2.0: New definitions were added, amended and updated. Clause 3.0: General Requirement was amended and updated. Clause 4.0: Key Responsibilities was amended and updated. Clause 5.1, 5.2, 5.3, 5.4, 5.5 & 5.7 was amended and updated. Clause 5.8 was newly added Clause 6 & 7 was amended and updated. Clause 8 was amended and updated. Appendix 1 was was newly added. Document formatting amendments












Appendix 1 - Specifications for Air Flow Meter A. Standards to be complied by the Air Flow Meter The air flow meter shall be manufactured manufact ured and tested as per requirement of and in conformance confor mance to standard of ANSI / ASHRAE 62.1 – 62.1 – 2010, 2010, IEC 664/NIOSH/OSHA/ACGIH or any equivalent international standard/code standard/code of practice.

B. Material and Construction: 

Large backlit liquid crystal display with large key pad

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Measurement Measurement Data:

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Velocity Volumetric Flow Rate o Temperature o Relative Humidity o Wet Bulb Temperature o Measurement Ranges: o

Velocity – Velocity – 0 - 6000 ft/min (0 to 30 m/s) Volumetric Volumetr ic Flow Rate – Rate – Actual Actual Range Range is a Function Function of Actual Velocity and and Duct o Size o














D. General: 

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Any deviation from or non-compliance non-complia nce with these specifications specifica tions shall be clearly stated with reasons by the manufacturer when submitting the bid. Documents regarding approvals, tests, tests, warranty, after after sales service, service, storage requirements and specification data sheets shall be submitted along with the offer. All instructions instruct ions shall be written in English and Arabic languages. Caution/warning Caution/warnin g notes shall be supplied. Instruction/operation Instruct ion/operation manual shall be supplied with each individual monitors. Date of manufacture manufactu re and expire shall be indicated.

KOC.ge.031 - Laboratory Safety and Hygiene Procedure

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