The Directorate of Factories, Government of Telangana on May 02, 2026, issued the High-Priority Safety Alert for Chemical R&D and QC Laboratories.
The following has been stated:
• The alert focuses on preventing accidents during laboratory operations and scale-up activities by strengthening containment systems, reaction safety, gas handling, flammable vapour monitoring, flameproof (FLP) equipment, and nitrogen safety management.
• Key provisions include strict use of fume hoods only for containment (not storage), mandatory HAZOP studies and calorimetry reviews before scaling up reactions, bonding and earthing during solvent transfer, and installation of continuous LEL (Lower Explosive Limit) monitoring systems.
• Laboratories handling flammable gases or solvents shall use certified FLP/Ex-rated electrical equipment, maintain gas cylinder inventories, and follow prescribed storage and segregation norms for compressed gases.
• The alert highlights nitrogen as a major asphyxiation hazard and requires oxygen-depletion sensors, permit-to-work procedures for nitrogen-purged spaces, trained personnel for purging operations, ventilation controls, buddy systems, and emergency response protocols. Before transferring any process from laboratory to plant, a documented Pre-Startup Safety Review (PSSR), hazard studies, vent sizing assessments, and hazardous-area classification reviews are mandatory.
• Factories shall complete a gap analysis within 30 days, install and calibrate LEL and oxygen sensors, update chemical compatibility matrices, train personnel, and submit compliance reports to the Inspector of Factories.
[SAFETY ALERT No. DOF-SA/LAB/08/2026]
