GENERAL LAB SAFETY

LABORATORY GENERAL SAFETY HAZARDS


Accidents in the laboratory are often the result of carelessness or ignorance either by you or by your neighbors. Stay alert and pay constant attention to your own and to your neighbors' actions. The safety precautions outlined below will be worthless unless you plan, understand, and think through the consequences of every operation before you perform it. The common accidents, which often occur simultaneously, are fire, explosion, chemical and thermal burns, cuts from broken glass tubing and thermometers, absorption of toxic, but non-corrosive chemicals through the skin, and inhalation of toxic fumes. Less common, but obviously dangerous, is the ingestion of a toxic chemical. Each of these types is discussed in a general way below, and more specific reference to certain hazards will be found in the individual experiments.

1. Fire: There should never be open flames in the lab. Make it a working rule that water is the only nonflammable liquid you are likely to encounter. Treat all others in the vicinity of a flame as you would gasoline.  
Display "No smoking signs" , visible all around.

It is your responsibility to yourself and to your neighbors to know where the nearest safety shower and fire extinguisher are located. 


2. Explosion. Never heat a closed system or conduct a reaction in a closed system.  Before starting a distillation or a chemical reaction, make sure that the system is vented. The results of an explosion are flying glass and spattered chemicals, usually both hot and corrosive.


3. Chemical and Thermal Burns: Be aware of the chemicals' properties and always use protective equipment.
Be careful with hot plates to avoid burns. Always assume that hot plates are HOT. 


4. Cuts:. The most common laboratory accident is probably the cut received while attempting to force a cork or rubber stopper onto a piece of glass tubing, a thermometer, or the side-arm of a distilling flask. Be sure to make a proper-sized hole, lubricate the cork or stopper (lubrication is essential with a rubber stopper), and use a gentle pressure with rotation on the glass part. Severed nerves and tendons are common results of injuries caused by improper manipulation of glass tubes and thermometers. Always pull rather than push on the glass when possible.


5. Absorption of Chemicals: Keep chemicals off the skin. Many organic substances are not corrosive, do not burn the skin, or seem to have any serious effects. They are, however, absorbed through the skin, sometimes with dire consequences. Others will give a serious allergic reaction upon repeated exposure, as evidenced by severe dermatitis. Be careful about touching your face or eyes in the lab; make sure your hands are clean first. Gloves will be available in the lab. However, gloves provide only a temporary layer of protection against chemicals on your skin and may be permeable to some chemical reagents, without visible deterioration. If your gloves come in contact with a chemical reagent, remove them, wash your hands, and get a new pair immediately.


6. Inhalation of Chemicals: Keep your nose away from chemicals. Many of the common solvents are extremely toxic if inhaled in any quantity or over a period of time. Do not evaporate excess solvents in the laboratory; use the hood or a suitable distillation apparatus with a condenser.  Specific safety information about chemicals used is included in each experiment write up. 


7. Ingestion of Chemicals: The common ways of accidentally ingesting harmful chemicals are: (1) by pipet, (2) from dirty hands, (3) contaminated food or drink and (4) food use of chemicals taken from the laboratory. Below are ways to avoid accidental ingestion of chemical reagents.


• Pipets must be fitted with suction bulbs to transfer chemicals. DO NOT USE MOUTH SUCTION.


• Wash your hands before handling anything (cigarettes, chewing gum, food) which goes into your mouth. Wash your hands when you leave the laboratory. 


• Do not eat or drink in the laboratory:  Use the water fountains for a drink--not a laboratory faucet. Remove gloves and wash your hands before using the water fountain or bathroom.

• Never use chemicals (salt, sugar, alcohol, bicarbonate, etc.) from the laboratory or stockroom on food. The source containers may be contaminated or mislabeled.


• Never use laboratory glassware as a food or drink container.


• Never store food or drink in a laboratory refrigerator or ice machine. Never consume ice from a laboratory ice machine.


GENERAL SAFETY RULES


Know the locations of the eyewash fountain, safety shower, fire blanket, and the fire extinguisher nearest to your laboratory bench. Be sure to know how to use this safety equipment. Your action during an emergency might prevent a classmate from serious injury.


WEAR SAFETY GLASSES AT ALL TIMES IN THE LABORATORY. 

Goggles are required to be worn at all times! Goggles are available to be worn over prescription glasses. 


WEAR SENSIBLE CLOTHING 
In the laboratory, sensible clothing includes shoes that fully cover the feet; protects from unseen hazards on the floor. Sensible clothing also includes old clothes, which are not too loose, especially at the sleeves. Laboratory coats or aprons are even more satisfactory.  Do not wear synthetics clothes if possible as they burn readily.

NEVER WORK ALONE IN THE LABORATORY
All work must be performed under the supervision of a laboratory instructor/demonstrator. The instructor should be aware of the exact nature of all work being done in the laboratory.


DO NOT PERFORM ANY UNAUTHORIZED EXPERIMENTS
Do only the experiment, which has been assigned by the laboratory instructor. Never do any unauthorized experiment/test in place of the one assigned by the instructor/supervisor. 

DO NOT EAT, DRINK OR SMOKE IN THE LABORATORY 
For safety purposes, assume all chemicals to be poisonous either by themselves or because of impurities. Also avoid direct contact with organic chemicals. Many are absorbed directly through the skin.


KEEP THE LABORATORY CLEAN AT ALL TIMES 
Any chemical spilled on your skin or your clothing, should be washed immediately and thoroughly. If a solution, a solid, or liquid chemical is spilled on the bench or on the laboratory floor, clean up the spill immediately. Make sure that your work area is clean and free of spilled chemicals or scraps of paper. Wash your hands with soap and water.


DISPOSE OF WASTE AND EXCESS MATERIALS IN THE PROPER MANNER
Used matches, paper, broken glass, or porcelain ware should be placed in the appropriate containers but not in the sinks or cup sinks. If you have any questions concerning the waste disposal, ask your instructor for the proper procedure.


USE THE FUME HOOD WHEN NECESSARY 
Use the fume hood when you are so directed, Fume hoods remove toxic vapors and irritating odors from the laboratory. The removal of these materials is essential for protecting the health and safety of those people working in the laboratory.


NEVER LOOK DIRECTLY into the mouth of an open flask or test tube if it contains a reaction mixture.


USE ONLY EQUIPMENT, WHICH IS IN GOOD CONDITION:   Defective equipment is an important source of 


GLOVES

Glove Types and Removal Gloves should be selected on the basis of the material being handled and the particular hazard involved. 
.
MIXING
If liquid chemicals are to be mixed with water, always add the concentrated chemical to water rather than the other way around. This keeps the new solution dilute at all times and avoids many accidents. Usually addition should be done slowly, using small quantities. It is especially important to add acid to water because of the heat generated.


DISPOSAL 
If the laboratory instructor directs you to dispose of any solid chemicals in the skin, flush it down the drain with copious amounts of running water. All other solids should be disposed of in special containers provided for this purpose.


IF AN ACCIDENT OCCURS
In spite of the best efforts of all concerned, accidents sometimes occur in the laboratory. Use good judgment and do not panic in case of an emergency. 


CHEMICAL SPILLS:
Locate spill cleanup materials. Laboratories should be equipped with spill cleanup kits. 
Wear the appropriate personal protective equipment (e.g., gloves, goggles) when cleaning up spills.

Acid Spills: 
Apply neutralizer (or sodium bicarbonate) to perimeter of spill. Mix thoroughly until fizzing and evolution of gas ceases. NOTE: It may be necessary to add water to the mixture to complete the reaction. Neutralizer has a tendency to absorb acid before fully neutralizing it. Check mixture with pH indicator paper to assure that the acid has been neutralized. 
Transfer the mixture to a plastic bag, tie shut, fill out a waste label, and place in the fume hood. Notify supervisor.
Caustic Spills
Apply neutralizer to perimeter of spill. Mix thoroughly until fizzing and evolution of gas ceases. Check mixture with pH indicator paper to assure that the material has been completely neutralized. 
Transfer the mixture to a plastic bag, tie shut, fill out a waste label, and place in the fume hood. Notify supervisor.
Solvent Spills 
Apply activated charcoal to the perimeter of the spill. Mix thoroughly until material is dry and no evidence of liquid solvent remains.
Transfer absorbed solvent to a plastic bag (if compatible), tie shut, fill out and attach a waste label, and place in the fume hood. Notify supervisor.
Mercury Spills 
Using a mercury vacuum, vacuum all areas where mercury was spilled with particular attention to corners, cracks, depressions and creases in flooring or table tops. Place the contaminated sponge in its plastic bag, tie shut, fill out and attach a waste label, and place in the fume hood. 


LARGE CHEMICAL SPILLS ON THE LABORATORY BENCH OR AREA


a.   If the material is not particularly volatile, nor toxic, and poses no fire hazard: 
Liquid can be cleaned up by using an absorbent material which neutralizes them, for example, sodium bicarbonate solution or powder for acids, or sodium thiosulfate solution for bromine. Rubber or plastic gloves should be worn while using absorbent materials. A dustpan and brush should be used to remove the absorbent material. Then, the contaminated area should be cleaned with soap or detergent and water; and the area mopped dry.


b.   If the material is volatile, flammable or toxic:
ALERT everyone in the laboratory to extinguish flames, disconnect spark-producing equipment, shut down all experiments, and evacuate the laboratory. The laboratory instructor will handle the clean up.


CHEMICAL SPILLS ON A PERSON


1. OVER A LARGE AREA: Within seconds, quickly remove all contaminated clothing while person is under safety shower. Flood the affected body area with cold water for at least fifteen minutes. If pain continues or resumes, flood with more water. Wash off chemicals with a mild detergent solution. Do not apply any materials such as neutralizing agents or salves, to the area. Obtain medial assistance immediately.

2. OVER A SMALL AREA: Immediately flush area thoroughly with cold water. Wash with a mild detergent solution. If there is no visible burn, scrub the area with warm water and soap.


3. IN THE EYES: You will need to assist the person who has chemicals spattered in the eyes. Immediately drench the eyes at the nearest emergency eyewash station. Force the eye or eyes open to get water into them. The speed of your response to this emergency is extremely important. Notify the laboratory instructor/supervisor of the accident immediately.


SWALLOWING CHEMICALS


The laboratory instructor should determine what specific substance ingested. 
The individual should be forced to drink copious amounts of water while en route to medical assistance. The Health Center or Hospital should be notified while the individual is in transit as to what chemicals are involved.


BURNS


For burns by hot objects, flames or chemical, flush the affected area with cold water for several minutes. Notify the laboratory instructor of the burn and he will arrange transportation to the infirmary if necessary.

INJURY OR ILLNESS


Render assistance if necessary. For minor cuts, wash them thoroughly, apply a good antiseptic, and a band-aid. For major cuts, severe bleeding or serious illness, send someone for help and administer first aid. Only a physician is trained to treat serious injury or illness. Notify the instructor immediately.




ELECTRICAL SAFETY 


NEVER WORK ALONE 

PREVENT ACCIDENTS: FOLLOW THIS ADVICE 


•  Never hurry. Work deliberately and carefully. 
•  Connect to the power source LAST. 
•  If  you  are  working  with  a lab kit that has internal power supplies,  turn the main power switch 
OFF  before  you  begin work on the circuits.  Wait a few seconds for power supply capacitors to 
discharge.  These steps will also help prevent damage to circuits. 
•  If  you are working with a circuit that will be connected to an external power supply,  turn the 
power switch of the external supply OFF before you begin work on the circuit. 
•  Check  circuit  power  supply  voltages  for proper value and for type (DC, AC, frequency) before 
energizing the circuit. 
•  Do not run wires over moving or rotating equipment, or on the floor,  or  string  them  across 
walkways from bench-to-bench. 
•  Remove conductive watch bands or chains, finger  rings, wrist watches, etc., and do not use 
metallic pencils, metal  or metal edge rulers, etc. when working with exposed circuits. 
•  When breaking an inductive circuit open the switch with your left hand and turn your face away to 
avoid danger from any arc which may occur across the switch terminals. 
•  When  using large electrolytic capacitors be sure to wait long enough (approximately five time 
constants) for the capacitors to discharge before working on the circuit. 
•  All conducting surfaces intended to be at ground potential should be connected together. 

SAFETY
Safety in the electrical laboratory, as everywhere else, is a matter of the knowledge of
potential hazards, following safety precautions, and common sense. .


Death is usually certain when 0.1 ampere or more flows through the head or upper thorax and have been fatal to persons with coronary conditions. 
The current depends on body resistance, the resistance between body and ground, and the
voltage source. 


If the skin is wet, the heart is weak, the body contact with ground is
large and direct, then 40 volts could be fatal. Therefore, never take a chance on "low"
voltage. 


When working in a laboratory, injuries such as burns, broken bones, sprains, or
damage to eyes are possible and precautions must be taken to avoid these as well as
the much less common fatal electrical shock. 


Make sure that you have handy emergency phone numbers to call for assistance if necessary. If any safety questions arise, consult the lab demonstrator or technical assistant / technician for guidance and
instructions. 


Observing proper safety precautions is important when working in the
laboratory to prevent harm to yourself or others. The most common hazard is the
electric shock which can be fatal if one is not careful.


Acquaint yourself with the location of the following safety items within the lab.


a. fire extinguisher
b. first aid kit
c. telephone and emergency numbers


Electric shock
Shock is caused by passing an electric current through the human body. The severity
depends mainly on the amount of current and is less function of the applied voltage.
The threshold of electric shock is about 1 mA which usually gives an unpleasant
tingling. 
For currents above 10 mA, severe muscle pain occurs and the victim can't let
go of the conductor due to muscle spasm. Current between 100 mA and 200 mA (50 Hz
AC) causes ventricular fibrillation of the heart and is most likely to be lethal.What is the voltage required for a fatal current to flow? This depends on the skin resistance. Wet skin can have a resistance as low as 150 Ohm and dry skin may have a resistance of 15 kOhm. Arms and legs have a resistance of about 100 Ohm and the
trunk 200 Ohm. 
This implies that 240 V can cause about 500 mA to flow in the body if
the skin is wet and thus be fatal. In addition skin resistance falls quickly at the point of
contact, so it is important to break the contact as quickly as possible to prevent the
current from rising to lethal levels.


Equipment grounding
Grounding is very important. Improper grounding can be the source of errors, noise and
a lot of trouble. Here we will focus on equipment grounding as a protection against
electrical shocks. Electric instruments and appliances have equipments casings that are
electrically insulated from the wires that carry the power. The isolation is provided by the
insulation of the wires as shown in the figure a below. However, if the wire insulation
gets damaged and makes contact to the casing, the casing will be at the high voltage
supplied by the wires. If the user touches the instrument he or she will feel the high
voltage.

If, while standing on a wet floor, a user simultaneously comes in contact with
the instrument case and a pipe or faucet connected to ground, a sizable current can
flow through him or her, as shown in Figure b. However, if the case is connected to the
ground by use of a third (ground) wire, the current will flow from the hot wire directly to
the ground and bypass the user as illustrated in figure c.


Equipments with a three wire cord is thus much safer to use. The ground wire (3rd wire)
which is connected to metal case, is also connected to the earth ground (usually a pipe
or bar in the ground) through the wall plug outlet.Always observe the following safety precautions when working in the laboratory:


OBSERVE THE FOLLOWING RULES:-


1. Do not work alone while working with high voltages or on energized electrical
equipment or electrically operated machinery like a drill.
2. Power must be switched off whenever an experiment or project is being
assembled, disassembled, or modified. Discharge any high voltage points to
grounds with a well insulated jumper. Remember that capacitors can store
dangerous quantities of energy.
3. Make measurements on live circuits or discharge capacitors with well insulated
probes keeping one hand behind your back or in your pocket. Do not allow any part
of your body to contact any part of the circuit or equipment connected to the circuit.
4. After switching power off, discharge any capacitors that were in the circuit. Do not
trust supposedly discharged capacitors. Certain types of capacitors can build up a
residual charge after being discharged. Use a shorting bar across the capacitor, and
keep it connected until ready for use. If you use electrolytic capacitors, do not :
· put excessive voltage across them
· put ac across them
· connect them in reverse polarity
5. Take extreme care when using tools that can cause short circuits if accidental
contact is made to other circuit elements. Only tools with insulated handles should
be used.
6. If a person comes in contact with a high voltage, immediately shut off power. Do not
attempt to remove a person in contact with a high voltage unless you are insulated
from them. If the victim is not breathing, apply CPR immediately continuing until
he/she is revived, and have someone dial emergency numbers for assistance.
7. Check wire current carrying capacity if you will be using high currents. Also make
sure your leads are rated to withstand the voltages you are using. This includes
instrument leads.
8. Avoid simultaneous touching of any metal chassis used as an enclosure for your
circuits and any pipes in the laboratory that may make contact with the earth, such
as a water pipe. Use a floating voltmeter to measure the voltage from ground to the
chassis to see if a hazardous potential difference exists.
9. Make sure that the lab instruments are at ground potential by using the ground
terminal supplied on the instrument. Never handle wet, damp, or ungrounded
electrical equipment.
10. Never touch electrical equipment while standing on a damp or metal floor.
11. Wearing a ring or watch can be hazardous in an electrical lab since such items make
good electrodes for the human body.
12. When using rotating machinery, place neckties or necklaces inside your shirt or,
better yet, remove them.
13. Never open field circuits of D-C motors because the resulting dangerously high
speeds may cause a "mechanical explosion".
14. Keep your eyes away from arcing points. High intensity arcs may seriously impair
your vision or a shower of molten copper may cause permanent eye injury.
15. Never operate the black circuit breakers on the main and branch circuit panels.
16. In an emergency all power in the laboratory can be switched off by depressing the
large red button on the main breaker panel. Locate it. It is to be used for
emergencies only.
17. Chairs and stools should be kept under benches when not in use. Sit upright on
chairs or stools keeping the feet on the floor. Be alert for wet floors near the stools.
18. Horseplay, running, or practical jokes must not occur in the laboratory.
19. Never use water on an electrical fire. If possible switch power off, then use CO2 or a
dry type fire extinguisher. Locate extinguishers and read operating instructions
before an emergency occurs.
20. Never plunge for a falling part of a live circuit such as leads or measuring equipment.
21. Never touch even one wire of a circuit; it may be hot.
22. Avoid heat dissipating surfaces of high wattage resistors and loads because they
can cause severe burns.
23. Keep clear of rotating machinery.Precautionary Steps Before Starting an Experiment so as Not to Waste Time Allocated.

LAB EQUIPMENT SAFETY DATA

LAB EQUIPMENT SAFETY


AUTO DISTILLATION UNIT


PURPOSE
Distillation test determine the distillation rang of petroleum products to specify the product composition and also help to assess the validity of the product. It also determines the molecular containments which would cause re-light problems at altitude or potential damage to the hot section of engine.


MAIN PARAMETERS
    BATH LIQUID : DISTILLED WATER (5 ◦C to 95 ◦C)
    LIQUID LEVEL :  2 – 5 cm below the cover plane

    MAINS POWER :  230 V +- 10%, 50/60Hz, 5A, 1400W
         
  OPERATING TEMPERATURE :  +10 to +35 *C


  SOFTWARE USED :  ONLY “ADUCON”


OPERATING INSTRUCTIONS

• Before switching on ADU-4, the printer has to be switched ON to make sure the Header will be printed with the actual date.
• When testing in boiling group 0, after taking out the graduated cylinder and cleaning the tube, the chamber has to be put into working position to avoid freezing of the cooling chamber.
• If the cooling chamber is not set into working position, no distilling test can be started. 
• When using your own cryostat, the use of connection tubes with an inner diameter of at least 10mm is strongly recommended.
• To avoid condensation out of the chamber, the cooling chamber has to be set into test position after having taken out the graduated cylinder.
• If during the test, the condenser temperature deviates more than +10% or above 61*C, the test is stopped automatically for safety reasons.
• During distillation, if there is deviation of more than +2ml/min, the program stops automatically for safety reasons.
• A missing or incorrectly placed drip tongue may be the reason for a lot of errors, insert it according to fig 11-0540M.
• If the display is not lighted after switch on, see the Fuse.
• If the sample-PT100 is broken or not connected, then the sample temperature will not be indicated.
• The mounting should only be done using gloves or appropriate protection. 
• Make use of safety goggles and gloves; provide fire extinguishing devices and functions.
• The device should be kept in protected place, protect from drought and sunlight.

WARNINGS:
 

• The heating device and the sample might be very HOT, avoid touching without protection.
• If distillation flask bursts during operation, the leaking sample and the glass splinters flying about might cause danger. (Use safety Goggles and Gloves).
• The magnetic valve for supply of extinguishing gas can only be switched, if mains voltage is there. It is connected dead! When there is fire, never disconnect from the mains or switch off the device. (This is in case of automatic fire extinguisher connected)
• Use only porous boiling stones for analytical purposes for distillation tests.
• Do not use boiling stones made of glass or Teflon. 
• Do not put boiling stones into hot liquid. 

MAINTENANCE

WEEKLY:
Cleaning of tempering chamber (place of measuring cylinder).
MONTHLY:
Check/refill of liquid level in circulating cooler.
YEARLY:
Calibration of temperature sensors for accuracy by specialist or trained user.
Calibration of tempering chamber for volume light barriers by specialist or trained user.

FLASH POINT UNIT

PURPOSE:
It determines the fuel contamination (mixing) of relatively non-volatile or non-flammable materials with volatile or flammable materials, if not conforming to the specified limits can cause on-board aircraft fires.


SUMMERY OF METHOD
PENSKY-MARTIN automated closed-cup apparatus is used with a slower (equilibrium) heating rate and constant pressure, applies an ignition source causing vapors of specimen of the sample to ignite under specified test conditions.


OPERATING INSTRUCTIONS
Check Flash Point Unit for cleanliness, security of electric wires, sensors and other connections.
Use a chilled sample.
Set values (parameters).


SAFE LIMIT: (FOR JP-8, FLASH SHOULD NOT OCCUR BEFORE 100 *F)

WARNINGS

• Test samples are flammable, volatile and toxic; always use safety glasses and protective clothing while operating the instrument.
• Tip of the igniter is fragile, handle with care.
• The IGNITER, LID, CUP and TEST AREA may be very hot, up to 400*C.
• Do not use Air Blast Pipe while sample cup is still located in the test area.
• While switching between the temperature units, the value currently displayed may not be converted. Always set the temperature units first, and then alter the other parameters.
• The maximum pressure of the compressed air for cooling (if used), must not exceed 670 KPA (100 PSI).
• Do not lubricate the dipping mechanism, the shutter and the stirrer.

MAINTENANCE

AFTER EACH TEST
Wipe the sample cup clean
Wipe the lid, shutter and stirrer clean
Wipe the sample probe clean
   
DAILY CHECKS
                            Check the cup, shutter, stirrer and sample probe for cleaning.
                           Wipe the exterior of the bath clean for spillage, splashes and residues.
SIX MONTHLY
                           Wipe the sample cup, lid, shutter, stirrer, sample probe and the exterior of the bath clean of                       spillages, splashes and residues. Thoroughly clean the Lid by removing the flash detector and sample part, use solvent soaked rag and then allow to dry air and then refit the flash detector and sample part. Check the stirrer Flexible Drive Shaft for damage of drive ends, tightness of grub screws and excessive permanent bend.
Wipe clean the exterior of the complete unit.


12 MONTHLY:
Calibration of Sample Part.

KV2 VISCOMETER BATH

SCOPE
This test method specifies procedure for the determination of the kinematics viscosity, “v” of liquid petroleum products, both transparent and opaque, by measuring the time for a volume of liquid to flow under gravity through a calibrated glass capillary viscometer. The dynamic viscosity, “n” can be obtained by multiplying the kinematics viscosity, “v” by the density, “p” of the liquid.


SIGNIFICANCE
Higher than specified limit create a combustor burner profile conductive to hot streaks and resultant combustor / turbine damage or potential failure.


SUMMERY OF METHOD
The time is measured for a fix volume of liquid to flow under gravity through the capillary of a calibrated viscometer under a reproducible driving head ands at a closely controlled and known temperature. The kinematics viscosity is the product of the measured flow time and the calibrating constant of the viscometer.
Taken sample of JP – 8 10ml in viscometer tube. Suck the sample fuel to red line upper level, and start the time, when the sample reach the lower red line stop the watch and note the time.


 Bath liquid =    Methyl Alcohol or De-Natured Ethyl Alcohol.
 Viscosity   =    Time / factor (65.29) = mm2 / s  
 Limit         =     8.0 mm2 / s


CHECKS BEFORE STARTING WORK

• Make use of safety goggles and protective clothing.
• Make sure that, Power requirement i.e. (220V 10A Fused), is correct.
• Fluid level 1.5 to 2.5 cm below the lip of test aperture at 20*C.
• Ambient temperature 30*C, temperature range +20*C to -40*C.

OPERATING INSTRUCTIONS

• Switch the mains on/off switch to “ON”.
• Check that the fluid level lamp is illuminated green.
• Switch the backlight on/off switch to “ON”.
• Check that the backlight lamp is illuminated green.
• Switch the stirrer on/off switch to “ON”.
• Check that the stirrer lamp is illuminated green.
• Check that the safety condition lamp is illuminated green.
• Check that the alarm lamp is “NOT” illuminated.
• Switch the refrigeration on/off switch to “ON”.
• Check that the refrigeration lamp is illuminated green.
• Follow the procedure set out in the method of test. 

MAINTENANCE
    6 Monthly :  Cleaning / Brushing of Air Grills.


    12 Monthly:-
Verification of temperature control system, according to Manual.
Low fluid level switch, testing according to Manual.




TWIN – COLUMN ADSORPTION APPARATUS 


SCOPE
The Twin Column Adsorption Apparatus is used to provide volume percent composition values on petroleum fraction containing saturate, olefins and aromatics according to their adsorption affinities on silica gel. Fluorescent dyes are used to visualize the fractions.


SIGNIFICANCE
The determination of the total volume percent of saturates, olefins and aromatics in petroleum fractions is important. This information is also important in characterizing petroleum fractions. Aromatics / Olefins could cause severe damage to hot section components and reduce turbine and combustor life.


SUMMARY OF METHOD
Fill the silica gel till 1410mm inside the tube, then drop fluorescent (di gel) dye as indicator from 2mm to 5mm. After that fill again silica gel till 1610mm then drop 0.75ml sample (JP-8) after filling the sample, fill isopropyl alcohol till the end and set pressure first on 14kpa for 2.5min then 34kpa for 2.5min again to adjust  the pressure constantly on 60kpa. Wait for more than 15min start to make the bands of colours such as red brown, intense blue and intense yellow then  take readings on the scale.


CALCULATIONS
Aromatics % volume   =       La / L X100
Olefins% volume        =        La / L X100
Saturates% volume    =        La / L X100


VISUAL CHECKS

• Check that the UV lamp is securely attached.
• Check that the glassware is secure and undamaged.
• Check the gas connections for tightness and any flexible gas pipes for cracking and hardening.       
• Check the mains lead and connector for signs of damage. Power required 220V AC 1A Fused.

OPERATION CHECKS

• Check that valve on the control panel operates smoothly.
• Check that the pressure gauges are functioning.
• The max pressure of the air/Nitrogen gas supply should be 110 KPA.

WARNING: -
Do not look directly at the UV light. Prolong viewing could cause damage  to the Eyes, use safety goggles.
Do not exceed the maximum pressure required by the test method otherwise   the Glass-ware may be pressurized and burst.

FT-IR SPECTROMETER

MODEL: SPECTRUM 100

PURPOSE
Spectrum 100 FT – IR spectrometer is used for quantities determination of corrosion inhibiter of both brands HI-TECH 515 & HI-TECH 580.


SIGNIFICANCE
Insufficient lubricity qualities of fuel could cause the excessive wear and premature failure of fuel system components and may even result in excessive wear of internal splices of fuel pumps. It provides corrosion protection and lubricates fuel system components.


PRINCIPLE OF WORK
It is a kind of spectrometer able to measure the different waves number in a spectrum, usually in the infrared regions. The infrared beam enters the sample compartment through an aperture on the left. After passing through the sample, it enters the detector area through an aperture on right side of the sample compartment.


OPERATING INSTRUCTIONS
Operate the machine and its software according to the Manual.
Give a warm up time to the machine, the instrument can take up to    2 hours to equilibrate (Two HRS warm up time).

WARNINGS AND INSTRUCTIONS

• Do make sure the instrument is properly connected to the grounded (earth provided) electrical supply of (100 to 230V). 
• Keep the instrument dry; avoid spilling liquid into the instrument. Clean external spills immediately, if it enters the main body, switch off the power and call the Perkins Elmer Engineer. 
• Do not look at internal LASER beam along its axis.
• Do not purge the instrument with flammable gas. Only use dry, clean and oil-free Nitrogen air.
• Keep the instrument indoor under ambient temperature 5*C to 40*C and relative humidity of 80% up to 31*C.
• Working temperature 15*C to 35*C and relative humidity 75% maximum (non-condensing). If your instrument is fitted with CsI optics, then humidity should not exceed 45%.
• During operation there should be a minimum gap of 6 inches between any surface and cooling louvers at the rear of the instrument.
• Provide a gap of 3 inches to the adjacent equipment and 18 inches gap on the top surface.
• Flammable solvents or samples should not be stored on or near the instrument. Handling of such materials during preparation should be performed in a safe area away from instrument such as a fume cabinet.
• The sample compartment is highly affected by humidity. While working with water-based samples open to the air, either purge the compartment or leave the cover open.
• Do not use damaged packs of Desiccant, and they have not been left in contact with the air.
• If all three sectors of the Desiccant indicator are pink or white, then you must change the Desiccant. DO NOT switch the instrument ON or OFF until all sectors are blue.

EXISTENT GUM TESTER

SCOPE
This test method covers the determination of the non volatile residue in aviation turbine fuels and gasoline’s.
SIGNIFICANCE
Excessive gum content in fuel brings about sticking of the valve steams and clogging of filters and other orifices in the fuel system. All these effects are reflected in uncertain engine performance. A max figure is specified as excessive quantities of gum in the fuel will lead to blocking of fine orifices in fuel system.


SUMMARY OF METHOD
A measured quantity of fuel is evaporated under controlled condition of temperature and pressure. For aviation gasoline’s and aviation turbine fuels, the resulting residue is weighted and reported as mg/100ml.


TEST LIMITS
FUEL MIN MAX

JP-8/JP-1  -       7.0 mg/100ml
100LL  -       3.0 mg/100ml  


WARNING AND INSTRUCTIONS:

• Always wear safety glasses and protective clothing.
• Some parts are very HOT take care.
• Check electrical, steam and air supply properly.
• Purge the system for use with steam and air first.
• Set the target temperature on DIGITAL TEMP CONTROLLER to 165 *C for air and 232 *C for steam use.

MAINTENANCE
CLEANING: Wipe spills immediately, clean and flush jet assemblies regularly.


VERIFICATION:

• Verify the Air and Steam flow settings every Six (6) month.
• Verify DIGITAL TEMP CONTROLLER every Six(6) months.
• Verify Over-temperature cut-out every 12 months.

FULTON STEAM BOILER

PURPOSE
The purpose of this boiler is to produce steam required for Existent Gum testing in the Gum Bath.


PARAMETERS:


POWER RATING:              12 KW

MAX ALLOWABLE TEMPERATURE:           200 *C
MAX ALLOWABLE PRESSURE:            6.2 Bar
TEST PRESSURE:          9.3 Bar
CAPACITY:          376 Kg/Hr


WARNING AND INSTRUCTIONS

• Before power ON, ensure door and panel are closed.
• Open the steam valve. 
• Open all the valves in the feed water line.
• Switch the power isolator switch to ON position, then press the Boiler ON/OFF switch to ON position.
• If the LOW WATER LEVEL “LED” is ON, ensure pump is running (in right direction) with alarm and the heater element light is “Extinguished” until the required level of water is maintained.
• Always isolate electrical supply while opening the Door or Top Panel.  

MAINTENANCE
DAILY INSPECTION:-

• Check that the water level control is working.
• Blow down the Boiler (in case of daily use).

WEEKLY INSPECTION:-

• Check external mounted tank for cleaning and obstruction.
• Door area and controls for signs of leakage and element contactors for operating correctly (depress manually).
• All fittings for signs of leakage.

3 MONTHLY

• Isolate water supply, blow down the boiler through blow down receptacle.
• Remove the element, check the excessive scale or corrosion, clean as required and examine the interior of the boiler for deposits of scale and sludge. Replace the element with new gas kit.
• Check all electrical connections for tightness.

COPPER CORROSION TESTER

SCOPE
Sulphur compounds could cause damage to the fuel nozzles, combustor and turbines.
This test method covers the detection of corrosiveness to Copper of aviation gasoline, aviation turbine fuel, automotive gasoline and natural gasoline having the Reid Vapour Pressure not greater than 18 PSI and certain other petroleum products. The copper strip corrosion test is designed to assess the relative degree of corrosivity of a petroleum product.

SUMMARY OF METHOD
A polished Copper Strip is immersed in a given quantity of sample and heated at    100 oC temperature for the period of two hours. At the end of this period the Copper Strip is removed, washed and compared with the ASTM Copper Strip Corrosion Standards.


TEST LIMITS

FUEL   MIN MAX          


JP-8  -  1
JP-1  -  1
100LL   -  1


OPERATIONAL CHECKS

• Check for cleanliness of bath and its liquid.
• Check for proper electric connections, security and ratings (220V AC 15A FUSED). Power consumption is 2.2KW.
• Set the Bath temperature to 100*C (Not more than 100*C).
• Clean the copper strips with Silicon carbide dust and fine emery paper of grade 500.
• Place the sample with strip in test tube in the bomb vessel and immersed in bath for 2 hours at 100*C. 

WARNING: Products of high vapour pressure (above 18 PSI) must not be   placed in 100*C Bath.

READ VAPOUR PRESSURE BATH

SCOPE
This test method provides procedure for the determination of vapor pressure of gasoline, Aviation Turbine fuel and other volatile petroleum products.


SIGNIFICANCE AND USE
Vapour pressure is an important physical property of volatile liquids. This test method is use to determine the vapour pressure at 100 ºF of petroleum products with initial boiling point above 0 ºC (32 ºF). Vapour pressure is critically important for both automotive and aviation gasoline’s, affecting starting, warm-up and tendency of vapour lock with high operating temperature and high altitude.


SUMMARY OF METHOD
The liquid chamber of the Vapour pressure apparatus is filled with chilled sample and connected to the vapour chamber that has been heated to 37.8 ºC (100 ºF) in a bath. The assembled apparatus is immersed in a bath at 37.8 ºC (100 ºF) until a constant pressure is observed. The reading suitably corrected is reported as the read vapour pressure.


TEST LIMITS


FUEL MIN MAX


JP-8 Negligible Negligible
100LL 5.5PSI 7.0 PSI


CHECKS REQUIRED

• Bath water level, 25mm beneath the bath rim.
• Desired temperature is 37.8 *C.
• Excess temperature protection is 45 *C. 

WARNING:

• Never operate the bath with out the   bath fluid in   the bath.
• While handling with manometer, ensure   that Mercury column is sealed and air tight and avoid its spillage because it can harm health. 

VACUUM PUMP (55L)

PURPOSE
This is used to produce vacuum required by SAFCON SAMPLER.


OPERATING INSTRUCTIONS

• Ensure electrical connection to 110 V AC supply.
• Ensure exhaust provision.
• Ensure proper air pipe connection.
• Observe the oil level glass window (oil level should not be below mid point of window. The system should not also be overfilled).
• Take every precaution to prevent foreign objects / particles from entering into the pump.

MAINTENANCE


WEEKLY:
                  Purge the pump by opening gas ballast valve and operating up to 45-60 minutes. (Valve open).


 ANNUALLY:
Change oil according to Manual.

SAFCON SAMPLER

PURPOSE
It is designed for portable line sampling to determine particulate contamination and colour ratings of aviation fuel.
SCOPE
Excessive particulate matter can cause blockage of filters, fuel jets, combustor streaking which could result in damage to the nozzle diaphragm and turbine brackets.


OPERATIONAL CHECKS

• Carry out initial checks.
• Flush the system (fuel lines) for every new sample.
• Adjust pressure to give flow of 1 to 2 Liters per minute.

MAINTENANCE CHECKS
Periodically check all the piping and components, for fuel leaks.

LABORATORY OVEN

WARNING AND INSTRUCTIONS

• Watch for electric connection (plug and wiring).
• Do not place flammable solvents or vapors in the oven.
• Do not place combustible materials in the oven.
• Do not place work directly on perforated oven bottom. Place the load vertically aligned. For    maximum uniformity the work should be placed in the middle of the oven workspace.
• Do not attempt to operate oven at temperatures above the maximum rating of the oven.
• For drying application the air circulation damper should be fully open to allow moisture to escape and be replaced by dry room air.
• Operate in normal mode only (not in weekly or programmed mode).
• When the oven is not in use the on-off switch must be turned off.

SETTING VALUES:- After holding down SET key for 3 seconds, the current operating mode flashes on display and can be altered by Push/Turn control knob.
If the Push/Turn control knob or the SET key, have not been operated for 30 seconds, the controller automatically returns to main menu.


MAINTENANCE
                                 CLEAN REGULARLY TO PREVENT DEPOSITS ON CHAMBER SURFACE.


QUARTERLY:-  Lubricate moving parts (door hinges & closures) using thin silicon grease. Check hinge screw for tightness.

X-RAY SULPHUR METER

MODEL RX-360SH

SCOPE
SULPHUR present in the distillate fuels can attack many metallic and non metallic materials. When the Doctor Test is found to be +ive for a given sample, then amount of Sulphur is calculated by X-RAY SULPHUR METER.


OPERATIONAL CHECKS

• Check power plug and wiring. Ensure rated voltage and frequency is available.
• Warm the system up for 30 minutes before usage.

CARE AND MAINTENANCE

• Do not put flammable matters near product.
• Do not expose to water drops, sunlight, shocks and vibrations.
• Do not disassemble, modify or repair the product.
• Turn off power supply at once at smoke or abnormal odor or noise.
• Turn off power supply during a long period suspension. 

MYLER FILM REPLACEMENT:

• Turn off the power supply, before starting the work.
• While removing and attaching a sample cell flange, perform carefully not to soil to be unable to touch internal parts (proportional counter).
• Analysis value direction may change after Miler film replacement, perform multi-point auto calibration.

AIR COMPRESSOR

PURPOSE
To provide constant supply of air to be used in GUM Bath.


TANK CAPACITY: 300 LTR
PRESSURE:         220 PSI




OPERATING INSTRUCTIONS


DAILY:

• Check / maintain oil level.
• Drain condensation from air receiver.
• Check condition of electric wiring, parts, hoses and pipes.
• Check V-belts and machine components.
• Check for any un-usual noise or vibrations.

WEEKLY:

• Clean air filters
• Clean all external part.

MONTHLY:
· Check / adjust belt pressure.


QUARTERLY: Change oil.

DEHUMIDIFIER

PURPOSE
This equipment is used to control the humidity of room containing sensitive Lab equipment.


WARNINGS AND INSTRUCTIONS

• Correct power supply requirement is 200 V AC to 240 V AC 48-53 Hz single phase 13 A protected supply.
• Before plugging on the power, turn the Humidity Control Switch to the OFF position.
• After power is plugged in, turn ON the machine and the switch should be on recommended position i.e 4 to 6.
• While turning off, first put the switch to OFF position, observe the fan and compressor cut off, then switch off mains power.
• The compressor will restart only after 3-4 minutes delay each time the compressor is turned off.
• Do not change the position of selector switch quickly while machine is ON. If the machine stop running at selected humidity level, it is normal, to check if the machine is working or not, move the control switch clock wise one degree to a lower unit, once the machine proves to work, level it ON for at least 2 minutes before turning the control switch to the correct position. This checking should not be done more than two times.
• Do not spill water or chemicals on the machine.
• Do not operate on a damaged cable or plug or machine itself.
• Disconnect power before cleaning or relocating.
• Do not place objects (heavy/sharp) on the top of machine.
• Do not tilt the machine to one side, keep it upright all the times. If tilted, must not be powered on for at least one hour. Keep away from obstruction (wall) 2 meters on front side and 6-8 inch rear side.
• Check the filter weekly and clean if necessary.

UPS

OPERATING INSTRUCTIONS

• Make sure that input voltage of the UPS matches the main supply voltage and grounding is properly done.
• After the mains utility (power supply) is made available, press the power ON button and wait for 10 seconds. Make sure that the utility LED and “power on” LED are ON.
• Now make sure that “Battery Low” Red LED is not ON. (if yes, then charge the UPS).
• Put the load ON, which should not be of higher power rating than that of UPS?

WARNINGS

• Do not touch the out put terminals directly (It has its own internal energy source).
• Do not open the casing for checking or repair etc. Do not open the batteries.
• Do not put out / put load until 7-10 seconds while starting the UPS. 

MAINTENANCE


(NO SPECIAL / PERIODIC MAINTENANCE REQUIRED)

• Avoid from dusty, corrosive (excessive moisture) and salty environments.
• Keep all its ventilation openings free from obstruction and keep 8 inch away from the wall.
• If the UPS remains un-used for 2-3 month, recharge for 12 hours.

Glass distillation unit

Scope
Glass distillation unit is Ideal for general Laboratory use capable of producing pyrogen free distilled water.
Features:
The Unit provides, 4 litres/hr. of distilled water produced through a power input of 3KW by a Chromium Plated heater housed in a horizontal Borosilicate Glass Boiler (Pyrex Brand Borosilicate Glass). Temperature of distillate 25oC - 40oCtested for ambient room temperature of 30oC.


Specifications:
Dimensions (w x d x h)
IPH 4 50cm x 15cm x 45cm
Weight 6 kg. approx.
Electrical 220/240V, 50/60Hz. Single phase.
Power 3KW Heater
Water Supply Min. Flow rate 1 Litre / min.
Min. Pressure 3 p.s.i


Warning and instructions:

• Carefully handle the apperatus, watch for pipe/hose joints, it should be tight and leakfree.
• Due to heavy electric load of 3kw,  ensure proper electrical connection (plug & cable).
• Avoid touching the heater when the instrument is ON.
• Ensure the 'inlet' and 'outlet' water pipe/hose are free of obstruction.
• Never operate the instrument for the number of hours continously ; (extra power consumption and overheating of electric cable and plug) 

Maintenance:
Weekly:   Drain the water and clean the apperatus thoroughly.
3 Monthly: Drain the water and clean the apperatus thoroughly.
                                Inspect for any damage or crack, check the pipe/hoses for obstruction and joints for   tightness (Purge or Clean if necessary). Inspect the Heater body, cable and plug for any damage/abnormality (Clean Carbon deposits on plug and socket).

FSII TEST KIT

SCOPE
Jet fuel naturally has a small amount of suspended water. To help protect the water in the fuel from freezing,
Icing inhibitors have a significant use in aviation fuel and can be extracted from the fuel with the presence of water This test is used to assure the additive content is at the proper concentrations using a specialized refractometer.


Refractometer:
A refractometer works on the principle of refraction, the bending of light waves as they pass from one substance into another. Factors that influence refraction include temperature and the physical properties of the medium through which the light is traveling.


Sample preparation instructions:

• Be sure that all sample container and measurement container are clean before use.
• Use the distilled water. (recommended)

      Sample proportion:


      Range:


Test Limit =
Nonlinear temperature compensation is automatic and insures that fluids read between 32 to 122°F (0 and 50°C) are measured accurately.


Safe handling:

• Proper safety glasses, gloves and protective clothing and equipment should be used.
• Properly dispose of all test fluids, clean refractometer and store in the case. Wash the other components with soapy water, rinse and dry.

Maintenance:
Calibration is automatic and does not require the use of special calibration solutions, or tools.

ANALYTICAL WEIGHING BALANCE

SCOPE
The analytical balance is used to measure mass to a very high degree of precision and accuracy. It measures to a high precision (0.1 mg or better). As it is more sophisticated, so requiring more care while handling and storage.


INSTRUCTIONS FOR USE

• Set up the balance on a stable, even surface (benchtop or floor) in a dust-free room.
• The required electric power must be filtered and stable. 
• Do not install the balance in a place with air flows, heavy thermal changes and vibrations.
• Level the balance using bubble and leveling feet. 
• Connect correct power supply (i.e 110 Volt AC) and wait a few seconds. The balance will automatically switch on.
• Wait 30 minutes from switch on.
• Calibrate the balance again every time it is removed from previous place. (Check balance calibration periodically).
• Never overload a lab balance. 
• Protect the balance from aggressive chemical vapours.
• Do avoid electric and magnetic fields around the balance. . Avoid spillages of liquid on to the balance.

SAYBOLT CHROMO METER

Purpose
Saybolt chromometer is used for quality control of highly refined liquids like undyed motor and aviation gasolines, jet fuels, naphtas, kerosene and petroleum waxes (if fitted with suitable attachment). It also determines if contaminants are present in fuel. It measures colour by comparing a column of sample against colour discs.
Procedure:
The equipment comprises of a graduated glass sample column with a clear glass base, and a plain glass tube with a three position turret containing colour filter discs(1/2, 1 & 2). An eyepiece provides a split-field view of both the column and tube. Illumination is from a light source in the base of the unit. The height of a column of sample is adjusted until it matches the colour disc in the reference tube. The height is then read off the graduations and expressed in Saybolt units.


Instructions:

• Rinse the sample column with the fuel sample to be tested and then fill it.
• Use the nearest colour disc first, then drain the fuel sample as required.
• Be careful not to spill the sample over the equipment, in case of spills wipe out immediately.

Maintenance:
From time to time check all hardware for tightness, if there is leak in drain petcock, replace the silicon grease sealant, or use new type of cock to avoid leakage or rapid damaging by solvents.


NOTE:- If the instrument does not operate, check for mains power supply, cable, plug, fuse and bulb. If the bulb is faulty, replace it.