6.

3 SAFETY IN LABORATORY

Generally every one’s feeling is that laboratory is one such area

where there is no possibility of an accident. But it is not really so.
Though the inventory and usage of chemicals in the laboratory is
meager as compared to process plants, the possibility of risks of
handling and using of chemicals is more or less equal as far as
accidents are concerned. Only the degree of loss varies. Hence, it
is always important to consider the laboratory hazards also with
equal note that of plants.
6.3.1 General Safety Precautions

1. In areas where chemicals are being used, stored or handled,

strictly avoid smoking, consuming any eatables and drinks.
2. Only approved laboratory procedures and the safe methods
laid down in this manual must be followed for carrying out all
laboratory tests and experiments.
3. Treat all chemical with respect. Some chemicals can injure
or even kill if they are not handled properly.
4. Read the labels on all the containers before use. Keep the
chemicals in original containers until used. Never put
chemical into unmarked or mislabeled containers. Even
drinking water should not be stored kept in containers used
in laboratory.
5. Do not distract other’s attention and concentrate on your job
at all times to prevent accidents.
6. Always keep your work area clean and tidy. Objects lying on
the ground can be hazardous and even small spills can be
slippery hence. Clean them immediately.
7. Test, requiring use of open flame shall be restricted &
allowed only in designated location.
8. Use had gloves, apron and eye protections while handling
acids & corrosive chemicals etc., to avoid injuries.
9. When drawing samples of toxic and corrosive chemicals use
proper protective equipments.
10. Chemical fires can start easily and spread quickly hence,
remove sources of fire sparks from areas where chemicals
are stored or used.
11. Certain airborne dusts of chemicals can explode sometimes,
so avoid all ignition sources in the area while working with
such chemicals.
12. Handle flammable chemicals with great respects. These
chemicals catch fire easily at normal temperatures and the
vaporus can explode violently by a spark, flame or heat
source.
13. The vaporus of nearly all-flammable chemicals are heavier
than air. This means that the vaporus can crawl along the
ground to distant flames and sparks then flash back to the
source.
14. Ground and electrically interconnect all drums, containers
before transferring flammable chemicals from one container
to another. This prevents the hazards arising out of the
source.
15. Keep all containers of flammable liquids closed when not in
use.
16. Empty containers are dangerous as they may contain
chemical vaporus or liquid residual, which can also be
explosive. Keep away from all ignition sources.
17. All laboratory personnel must be familiar with location and
the use of fire extinguishers, eye baths, fire blankets, gas
masks and electrical switches.
18. Fire safety equipment should not be blocked by placement of
materials.
19. When there is a spill or leak of chemicals, extinguish all
sources of flame or sparks. Shut off the leak if safe to do so.
20. If hazardous chemical are spilled or released, evacuate the
area immediately and re-enter only when you have worn the
proper protective equipment. Do not operate any electrical
switch as this may generate spark.
21. Ensure proper ventilation while working in the laboratory.
22. Do not depend on your sense of smell to warm you about
vapours. Some chemicals can be hazardous in
concentration too low to detect by smell. Other can deaden
your sense of smell.
23. Use all protective equipment precisely while handling
hazardous chemicals. Before using any respirator check for
proper operation.
24. Wash your hands thoroughly with soap and water after
handling any chemical or containers of chemicals. Always
wash before eating, smoking or using toilet facilities.
25. Laboratory electrical equipments should be properly earthen
and one should ensure that before using the equipments.
26. No electrical equipment should be tampered by unauthorised
persons.
27. Electrically operated equipments must be switched off
immediately after use.
28. Water supply to laboratory condensers should be turned off
at the end of the day shift.

These are general guidelines. Follow instructions detailed under

individual heads.
6.3.2 Common Cause of Laboratory Accidents

1. Improper handling & storage of chemicals.

2. Improper techniques of usage & storage of laboratory
equipments.
3. Bad housekeeping.

6.3.2.1 Handing & Storage of Chemicals

6.3.2.1.1 Handling of Chemicals

1. Acids
Operate under the chemical fume removal hood whenever
heating acid or performing reactions, which may liberate acid
fumes. When making reagents always add acid to water,
keep acid off skin and protect eyes from splattering. Use
protective safety appliances during handling acids.

2. Alkalies

Alkalies can burn skin, eyes and respiratory tract severely.

Wear heavy rubber gloves and face shield to protect against
concentrated liquids. Use effective fume removal device or
gas mask to protect respiratory tract against alkali, dusts or
vapours. Protect skin and eyes when working with alkalies
as solids or concentrated solution.

3. Flammable Liquids

a. When using flammable, keep only required quantity in

the work area for immediate needs.
b. Store extra flammable chemicals in a separate place.
c. While transferring form a large container to small
container, ensure proper boding and earthing to avoid
static electricity hazard.
d. Keep all ignition sources away while working with
flammable chemicals.
e. Avoid spillage of flammable chemicals and in case
there is spillage, clean the area of once and put the
waste in a bin in safe area.

4. Toxic Chemicals
a. Check up the label properly before you move or open
or use the contents in it.
b. Use appropriate protective equipment before handling
toxic chemicals.
 c. Use only suction bulb (aspirator bulb) for drawing
toxic chemicals along with pipe. Do not suck
‘Chemicals’ with mouth.
d. Hot materials shall not be poured into a sink or drain
as the presence of water in the drain might cause
violent spattering. All waste toxic materials should be
properly disposed off before draining them.

6.3.2.1.2 Storage of Chemicals in Laboratory

1. Chemicals which might react together to give off dangerous

fumes or cause fires or explosion on accidental breakage
should be stored away from one another.
2. Volatile liquids should not be stored near heat sources or
placed in direct sun light.
3. Stock reagents are best stored on open shelves within easy
reach.
4. The largest containers may be stored on the bottom of the
shelves.
5. The corrosive materials should be deep enough to hold
contents of bottles if leakage occurs.

6.3.2.2 Handling & Storage of Laboratory Equipments

6.3.2.2.1 Handling of Laboratory Equipments

Glass Apparatus

1. Discard irreparable, cracked or broken glass apparatus into

properly labeled dustbin. Glass apparatus should be
supported and braced in a manner, which will not result in
excessive strain.
2. Do not use glass bottles for liquids having vapour pressure
above 15 psi at 1000 F (1 kg. At 380 C).
3. Discard defective bottles immediately. Wear dry rubber
gloves, goggles, gum boots and a rubber apron while
handling bottles of acids or other corrosive chemicals are
spilled on the skin or clothing, flood the affected area with
copious amount of water.
4. Do not force glass tubes or thermometers in or out of
stoppers when dismantaling equipment. If the stopper gets
stuck cut them away from the tubes. One should protect his
hands by a dust cloth or towel while inserting glass tubes in
corks.
 5. While using glass apparatus for heating or vacuum/pressure
service, check for quality of glass and its withstanding
capacity.

Ovens & Other Heating Media

Check frequently the operation and accuracy of oven. Heating

mantles, Hot Plates, Muffle furnace, & Liquid baths etc.
temperature regulators and thermometers.
Fume Cupboards

Remove all non-essential apparatus and chemicals before working

in the cupboard. Keep the windows lowered except removing or
introducing apparatus or chemicals. Transferring of all fuming
liquids, acids, toxic chemicals should be done under the fume
cupboard to avoid gaseous pollution in the lab.

Centrifuges

The manufacturers must not operate centrifuges at speeds

exceeding those maximums recommended. If excessive vibrations
occur during operations, stop the centrifuge acid do not resume its
operation until the cause of the vibration has been eliminated.

Desiccators

Keep the ground glass surfaces of desiccators greased. Seal and

unseal desiccators by a siding action of the lids. Never seal a
desiccators until its contents have cooled to a reasonable
temperature.

6.3.2.2.2 Safe Storage of Laboratory Equipments

1. Vacuum desiccators and other glassware in which vacuum is

created should be protected with a screen basket packed
with asbestos wool.
2. Store glass tubing and rods in a horizontal position with no
place protruding over the coping.
3. Store delicate glassware in separate cartons clearly marked
for ready identification.
4. Store glassware not higher than a person can reach easily
without standing on a stepladder.
5. Store heavy pieces on lower shelves. Store tall pieces at the
back, smaller ones towards the front of the shelf.
6. Special metal or plastic containers should be used to
transport bottles of acids, alkalies etc.
6.3.2.3 Housekeeping

1. Great care should be taken to keep the working

2. The spillages of chemicals should be immediately cleaned
and floors should be washed with water and mopped up with
a dry cloth.
3. One should clean the sinks only after ensuring that broken
glass pieces ate not lying in the sink.
4. It is always necessary to keep proper labels on the reagent
bottles and on sampling bottles to avoid complications.
5. The glassware, laboratory reagents, chemical should always
be kept in their appropriate places after use.
6. Colour coding on various pipelines should be strictly
followed.

6.3.3 Safe Methods of Working]

1. When distilling solvents, hydrocarbons or other liquids, do

not fill a distillation flask to more than ¾ the of its rated
capacity. Use bumping stones in distillation flask where
bumping may occur.
2. Never bring leaking sample containers into laboratory.
Charged pressure sample containers should be stored
outdoors and taken into the laboratory only when it is
necessary to transfer the samples to apparatus.
3. Use only approved ladders in good condition for climbing.
Grip the ladder with both hands while ascending or
descending. When using a portable ladder, station a person
at its foot to hold it. Never place a ladder in front of an
unlocked door.
4. Consider all electric wires with defective insulation as live
and dangerous. Do not overload electrical equipments. or
use for any purpose other than that for which it was
designed. When a liquid has been spilled over an electrical
equipments, first of all turn off the current and then clean the
equipment thoroughly and dry. Do not tamper with electrical
equipment. consult the concerned electrical persons. When
you find any electrical problem.
5. It is always important to remember the location or first aid
fire fighting equipment, eye wash showers, emergency
safety equipments etc. in the laboratory.
6. Gas burners should not be left unattended. The gas line
tubing to be checked for leakages time to time.
7. Hot plates should not be kept in ‘ON’ conditions when it is
not in use. All flammable and combustible materials should
be kept away form hot plates.
8. It is always important to keep the working area neat and
clean to avoid any kind of untoward incidents because of
bad housekeeping.
9. Avoid keeping different chemicals in the same container.
The practice of keeping laboratory chemicals in a refrigerator
along with drinking water should be avoided. Do not keep
food items drinks in refrigerator meant for storing of
chemicals.
10. While drawing chemicals in bottles from stores, they should
be securely transferred on a trolley made for such bottles.
11. While drawing chemicals form the plants all safety
precautions should be followed.
a. While drawing samples like Lactam, there is every
possibility of choking in the sampling point. Due care
should be exercised while removing the choking.
b. At the time of drawing liquid gaseous samples, it is
always important to drain the initial hold up by
opening the valve very slowly to avoid sudden
splashing.
c. Before drawing samples, one should ensure that the
sample is sufficiently cooled in the cool pot, to avoid
cracking of sampling bottles.
d. After drawing samples, a label should be put
immediately on the sampling bottles.
e. The person collecting the sample should wear the
personnel protective equipment like hand gloves, face
shield etc.
f. Only authorized persons should collect the samples.

12. Do not try to mix all the remnant chemicals after analysis for
disposal. They should be treated individually as per the laid
down procedure.
13. Chemicals, which are required to be stored in dark area,
should not get exposed to sunlight.
14. Safety glass/Face shield needs be used while working with
corrosive chemicals such as acids and alkalies so that a
splash to the eyes can be avoided.
15. While cutting glass rods using glasscutters, wear a face
shield. Towels may be placed over the rod to protect the
finger and the hands before breaking the piece.
16. Glassware to be heated by an open flame should be rested
on an iron wire mesh with an asbestos center to prevent the
 flame form coming in contact with the glass above the level
of the liquid. This will avoid cracking of the vessel.
17. Pressure flasks, which are to be heated under temperature
control by a water bath or electric oven should be shielded
so that in the event if the flask is ruptured, its contents and
fragments of broken glass will be safety deflected.
18. Pressure should be released from or applied to glass
vessels slowly.
19. It is generally unsafe to put pressure on laboratory
glassware to expel its contents.
20. Fill reagent and other bottles not more than 3/4th of their
capacity at room temperature leaving one fourth of the
capacity as outage to allow for expansion.
21. Severe vibration of a vacuum container may result in
collapse, equivalent to the shattering effect of an explosion.
Vacuum desiccators may be transported in a wooden box.
22. Carry beakers and all usual shapes of flasks and bottles with
the fingers around the body of the vessel. Do not grasp or
hold the volumetric and other long neck flasks at both top
and bottom when their contents are being agitated.
23. In washing glassware, no more than gentle pressure should
be applied in wiping the insides.
24. Cracked glassware or glassware with sharp or broken edges
should be either fire polished or destroyed.
25. The procedure for inserting glass tubing in stopper or rubber
tubing is as follows.
a. Never attempt to insert glass tubing having a jagged
end
b. Cut the glass tubing so that it has a smooth face, and
then fire polish it. If it can not be fire polished, level
the edge with the fire
c. Bore the hole in the stopper large enough to obtain a
snug fit without forcing. Select the rubber tubing
which is slightly smaller in diameter than be glass
tube
d. Use water, soap solution, glycerin or Vaseline as
lubricant to force the tube into the hole by a rotating
motion
e. The stopper should be grasped firmly in one hand and
the glass tubing with the other. Always aim tubing
away the palm of the hand holding the stopper or
rubber. Use napkin cloth to protect palm/fingers.
6.3.4 Handling of Gas Cylinders in Laboratory

1. Keep all the Gas Cylinders outside the laboratory building in

a ventilated roofed cylinder house. Required gases should
be drawn in the laboratory through a well-designed gas
distribution system.
2. Keep all compressed cylinders in upright position duly
secured with a chain to avoid free fall.
3. While operating with compressed cylinders proper care
should be taken by taking appropriate spanner for opening
and closing the valves. Using wrong tools for this purpose is
forbidden.
4. Do not apply grease, wax or any oil etc. to compressed gas
cylinder valves for lubrication.
5. Use soap water for checking the leakage in the valve of the
cylinder/gas distribution system. Note down pressure of
cylinders at regular intervals to notice the leaks, if any.
6. Do not drop the cylinders while handling. Use only cylinder
trolleys for transferring.
7. Do not try to tamper or damage the regulator valves of the cylinder.
Bring it to the notice of the concerned person in case you find any
problem with the regulator.
8. Do not keep oxygen cylinders along with flammable gases like hydrogen,
acetylene etc.

6.3.5 Waste Disposal

It is always important to dispose off chemicals after the experiments

are over as it is dangerous to keep them exposed for long time.

Acids

All waste acidic chemicals should be neutralized with soda ash or

lime or caustic soda solution before throwing them into drain.

Alkalies

All alkaline chemicals should be neutralized using acids before

disposing them off into drain.

Toxic Chemicals

No toxic chemical should be drained before detoxifying its effect.

They should be disposed off using specified procedure given in the
laboratory operating manuals.
 Flammable and Combustible Chemicals

Any spill or waste combustible and flammable chemicals should be

collected in a container and send them for BOD reduction to
Effluent Treatment Plant time to time.
6.3.6 Some Incompatible Chemicals
_________________________________________________________
Sr. Chemical Incompatible Chemicals
No.

1. Acetone Bromine. Chlorine. Nitric Acid & Sulphuric Acid

2. Acetylene Bromine, Chlorine, Copper, Fluorine, Mercury and
Silver
3. Alkaline Materials Carbon dioxide, Chlorinated hydrocarbons, Water
(NaOH, KOH) and the Halogens
4. Ammonia (Anhydrous) Bromine Calcium, Hypochlorite, Chlorine,
Hydrofluoric Acid, Iodine, Mercury and Silver
5. Chlorine Acetone, Acetylene, Ammonia Benzene Butadiene,
Butane and Other Petroleum gases, Hydrogen,
Finely divided Metals, Sodium Carbide &
Turpentine.
6. Fammable Liquids Ammonium nitrate, Chromic Acid, hydrogen
peroxide,
Nitric Acid, Sodium peroxide & the Halogens
7. Hydrocarbons such as Bromine, Chlorine, Chromic Acid, Fluorine,
Benzene, butane, Hydrogen Peroxide & Sodium peroxide,
Propane Gasoline,
Turpentine etc.
8. Hydrazine Hydrogen persuade, Nitric Acid and other Oxidant
9. Oxygen (Liquid or Flammable gases, liquids or solids such as
Enriched air) Acetone, Acetylene, Grease, Hydrogen, Oil and
Phosphorous
10. Sulphur Any oxidizing materials
11. Sulphuric Acid Chlorates, Perchlorates & Permanganates
12. Water Acetyl chloride, Carbides, Chromic Acid,
Phosphorous oxychloride, Phosphorous
Pentachloride, Sulphuric Acid and Sulphur trioxide
13. Alkaline metals Carbon tetra chlorides or Chlorinated
Such as Powdered Hydrocarbons, Carbon dioxide and the Halogens
Aluminum or
Magnesium Sodium,
Potassium etc
14. Acetic Acid Chromic & Nitric Acids, Hydroxyl compounds,
Ethylene glycol, Perchloric acid, Peroxides,
Permanganates
15. Aniline Nitric Acid, Hydrogen peroxide
16. Carbon activated Calcium, Hypochloride, all oxidizing agents
17. Copper Acetylene, Hydrogen peroxide
18. Chlorates Ammonia salts, Acids, Metal powders, Sulphur,
Finely divided organic or combustible materials
19. Chromic Acetic Acid, Naphthalene, Camphor, Glycerin,
Turpentine, Alcohol and Flammable materials
20. Fluorine Isolate from everything
21. Hydrocyanic Acid Nitric Acid, Alkalies
22. Hydrofluoric Acid Ammonia, aqueous & anhydrous
23. Hydrogen sulphide Fuming Nitric Acid, oxidizing gases
24. lodine Acetylene, Ammonia, Hydrogen
25. Mercury Acetylene. Fulminic acid, Ammonia
26. Nitric Acid Acetic Acid, Aniline, Chromic Acid. Hydrocyanic
Acid, Hydrogen sulphide Flammable liquids and
Gases
27. Oxalic Acid Silver, Mercury
28. Potassium chlorate Sulphuric and other Acids
29. Potassium perchlorate Sulphuric and other Acids
30. Potassium permanganate Glycerin, Ethylene, Glycol,
Benzaldehyde Sulphuric
Acid
31. Sodium Peroxide Ethyl & Methyl alcohols, Glacial Acetic Acid, Acetic
anhydride, Benzaldehyde, Carbon disulphide, glycerin,
Ethyl & Methyl acetates, Furfural
32. Phosphoric Acid Chlorides, Nitromethane, Sodium Tetrahydroborate
33. Perchloric acid Acetonitrile, Alochohols, combustibles dehydrating
agents
34. Potassium Nitrate Powdered metals, Organic materials reducing agents,
Sodium, Benzene trichloro ethylene, Zinc etc.
35. Sodium Nitrite Organic matter, Cyanides Butadiene Reducants. Urea,
Wood. Sodium amide sodium disulphite etc.
36. Chloroform Dinitrogen tetraoxide, Fluorine. Metals
trisopropylphosphine
37. Pyridine Oxidising materials
38. Trichloro ethylene Al, Ba, N2O4, Li, Mg, Liquid O2, O3 KOH, KNO3, Na,
NaOH, Ti
39. Phenol Oxidising materials, Formaldehyde, Butadiene
40. Carbon Tetra Chloride Aluminium Trichloride, Dibenzoyl peroxide, Potassium
tert-butoxide
41. Formaldehyde NO, performic Acid Nitromethane Magnesium
Carbonate, H2O2
42. Methanol Beryllium, Dihydride, Oxidants, Potasium terbutoxide,
Dichloromethane
43. Solvent Ethers Powerful oxidesers
44. Kerosene Oxidising materials
45. Hydrogen peroxide Charcoal, Coal, Metals, Metal oxides Metal salt,
Dimethyl phenylphorphine Hydrogen salenide Lithium
tetrahy-droluminate, Phosphorus, Phosphorus
(V) oxide, Tin (11) Chloride, unsaturated organic
Compounds
46. Oxalic acid Ag, Naclo3, Naocl
47. Boric acid K (CH3CO)2O