GC Kundu

Chief Manager(Fire & Safety)

Haldia Refinery

Fire Hazards & its Control

FIREFIRE

THE GREATEST BENEFACTOR TO HUMAN THE GREATEST BENEFACTOR TO HUMAN

CIVILISATION BUT ALSO CIVILISATION BUT ALSO

THE CRUELEST DEVASTATOR OF HUMAN LIFE,THE CRUELEST DEVASTATOR OF HUMAN LIFE,

PROPERTY AND ENVIRONMENTPROPERTY AND ENVIRONMENT

THE SUCCESS TO ELIMINATE / REDUCE FIRE

LOSS DEPENDS ON PROPER KNOWLEDGE OF

RISK AND ENFORCEMENT OF SOUND FIRE

SAFETY PROGRAMME

FIRE SCIENCEFIRE SCIENCE

IT CAN BE DEFINED AS THE KNOWLEDGE OF

FACTS LEADING TO PREVENTION OF FIRE

AND ITS CONTROL

FIRE PREVENTION

FIRE PROTECTION

FIRE FIGHTING

LIFE SAFETY SECURITY

PROPERTY PROTECTION

LIMITED DOWNTIME

IGNITION CONTROL

FUEL CONTROL

OCCUPANT PROTECTION

DETECTION AND SUPRESSION ACTIVITIES

PLANNING AND TRAINING

OPERATIONS

CONTROL

various IGNITION

SOURCES

1. CONTROL

QUANTITY

OF FUEL

1. PROVIDE

RELIABLE

EVACUATION

TO SECURE

AREA

1. PROVIDE

EARLY

WARNING

DETECTION

1. PROVIDE STAFF

EDUCATION &

TRAINING

2. CONTROL

TYPES OF

FUEL

2. PROVIDE

FEATURES

FOR

‘DEFEND IN’

PLACES

OCCUPANCY

2. PROVIDE

RELIABLE

ALARM

SYSTEM

2. PLAN

EMERGENCY

PROCEDURE

3. CONTROL

FUEL

ARRAN-

GEMENT

3. PROVIDE

RELIABLE

SUPRESSION

SYSTEM

Latest advancements in Fire Safety approach Focus on Passive Fire Protection Efficient Active Fire Protection Environment Friendly Extinguishants User Friendly Fire Fighting Equipments Advanced Smoke Management

Techniques Early warning and Detection Devices

5

FIRE RISK MANAGEMENT PHILISOPHY

• ANY INSTALLATION WHICH STORES AND HANDLES LARGE QUANTITY OF FLAMMABLE MATERIALS POSE THREAT TO THE SURROUNDING IN ADDITION TO ITS OWN SAFETY. IT THEREFORE, NECESSITATES THE INTRODUCTION OF INBUILT FIRE PREVENTION & FIRE PROTECTION FACILITIES.

• IT IS IMPRACTICAL AND PROHIBITIVELY COSTLY TO DESIGN FIRE PROTECTION FACILITIES TO CONTROL ALL CATASTROPHIC FIRES. USUAL REQUIREMENT OF A GOOD SYSTEM IS TO PREVENT EMERGENCIES FROM DEVELOPING INTO MAJOR THREAT TO THE INSTALLATIONS AND SURROUNDINGS.

CLASSIFICATION OF PETROLEUM PRODUCTSCLASS –A : LIQUID WHICH HAVE FLASH POINT BELOW 23OC.

CLASS – B : LIQUIDS WHICH HAVE FLASH POINT OF 23OC AND ABOVE BUT BELOW 65OC

CLASS – C: LIQUID WHICH HAVE FLASH POINT OF 65OC AND ABOVE BUT BELOW 93OC.

EXCLUDED PETROLEUM : LIQUID WHICH HAVE FLASH POINT OF 93OC AND ABOVE.

LPG DO NOT FALL UNDER THIS CLASSIFICATION BUT FORM SEPARATE CATEGORY.

DEFINITIONSFLASH POINT

THE FLASH POINT OF A LIQUID IS THE LOWEST TEMPERATURE AT

WHICH SUFFICIENT VAPOUR GIVEN OFF TO FLASH ON THE

APPLICATION OF FLAME IN THE PRESENCE OF AIR.

AUTO – IGNITION

THE LOWEST TEMPERATURE TO WHICH A SOLID ,LIQUID OR GAS

REQUIRES TO BE RAISED TO CAUSE SELF-SUSTAINED

COMBUSTION WITHOUT INITIATION BY A SPARK OR FLAME.

EXPLOSIVE LIMITS

EXPLOSIVE LIMITS ARE THOSE CONCENTRATIONS OF A VAPOR OR

GAS IN AIR BELOW OR ABOVE WHICH PROPAGATION OF A FLAME

DOES NOT OCCUR ON CONTACT WITH A SOURCE OF IGNITION.

THE LOWER EXPLOSIVE LIMIT IS THE MINIMUM CONCENTRATION

BELOW WHICH THE VAPOR AIR MIXTURE IS TOO LEAN TO BURN

OR EXPLODE.

THE UPPER EXPLOSIVE LIMIT IS THE MAXIMUM CONCENTRATION

ABOVE WHICH THE VAPOR AIR MIXTURE IS TOO RICH TO BURN OR

EXPLODE.

AUTO IGNITION, FLASH POINT AND EXPLOSIVE LIMITS OF SOME

OF THE PETROLEUM PRODUCTS S. NO.

MATERIAL AUTO IGNITION TEMPERATURE oC

FLASH POINT OC

EXPOSING RANGE VOLUME % IN AIR LOWER LIMIT UPPER LIMIT

1 CRUDE OIL DEPENDS UPON THE NATURE OF CRUDE

19 DEPENDS UPON THE NATURE OF CRUDE

2. HYDROGEN 585 GAS 4.1 74.0

3 METHANE 538 GAS 5.0 15.0

4 ETHANE 514 GAS 3.0 12.5

5 PROPANE 466 GAS 2.4 9.5

6 BUTANE 430 GAS 1.5 9.0

7 BENZENE 563 -11 1.3 7.1

8 TOLUENE 536 4.5 1.2 7.2

9 NAPHTHA 288 -18 1.1 5.9

10 GASOLINE 245 -7 1.4 7.6

11 ATF 254.4 38 0.7 5

12 SKO 254 35 0.7 5

AUTO IGNITION, FLASH POINT AND EXPLOSIVE LIMITS OF SOME OF THE PETROLEUM PRODUCTS

S. NO.

MATERIAL AUTO IGNITION TEMPERATURE

FLASH POINT OC

EXPOSING RANGE VOLUME % IN AIR LOWER LIMIT UPPER LIMIT

13 HSD 256 32 0.7 5

14 LDO - 66 - -

15 LSHS 316 66-166 - -

16 HSHS - 65.6-148.9 - -

17 FO 262-407 - - -

18 BITUMEN 485 205 - -

19 RAW COKE - 315.6 - -

20 PHENOL EXTRACT 715 80 - -

21 SLACK WAX 245 198.9 - -

22 MINERAL TURPENTINE OIL

253.3 32.2 - -

23 LPG 405-450 GAS 1.8 9.6

FIRE

FIRE IS A RAPID, SELF-SUSTAINED OXIDATION PROCESS

ACCOMPANIED BY THE RELEASE OF ENERGY IN THE FORM OF

HEAT AND LIGHT OF VARYING INTENSITY.

FIRE RESULTS FROM THE COMBINATION OF FUEL, HEAT AND

OXYGEN. WHEN A SUBSTANCE IS HEATED TO A CERTAIN

TEMPERATURE CALLED THE ‘IGNITION TEMPERATURE’ THE

MATERIAL WILL IGNITE AND CONTINUE TO BURN AS LONG AS

THERE IS FUEL, THE PROPER TEMPERATURE AND A SUPPLY OF

OXYGEN (AIR).

FIRE TRIANGLE

HEAT

FUEL

OXYGEN

METHODS OF EXTINGUISHMENTS OF FIRE1. STARVATION : ELIMINATION OF FUEL

2. SMOTHERING : LIMITING OF OXYGEN

3. COOLING : LIMITING TEMPERATURE

STARVATION : STARVATION IS ACCOMPLISHED BY REMOVING

COMBUSTIBLES FROM THE NEIGHBOURHOOD OF THE FIRE OR BY

REMOVING FIRE FORM THE MASS OF COMBUSTIBLE MATERIALS.

IT IS ALSO ACHIEVED BY SUBDIVIDING BURNING MATERIALS TO

SMALL ISOLATED POCKETS OF FIRE.

SMOTHERING : SMOTHERING IS ACCOMPLISHED BY ELIMINATING

OR DILUTING THE AVAILABLE OXYGEN WITH INERT GAS OR

COVERING THE FUEL SURFACE BY A SMOTHERING AGENT LIKE

FOAM.

COOLING : IF THE RATE AT WHICH HEAT IS GENERATED BY

COMBUSTION IS LESS THAN THE RATE AT WHICH IT IS GETTING

DISSIPATED THEN THE COMBUSTION CANNOT PERSIST.

APPLICATION OF WATER JET OR SPRAY TO A FIRE RESULTS IN

ITS EXTINGUISHMENTS BY THIS FUNDAMENTAL PRINCIPLE.

CLASSIFICATION OF FIRE INDIAN STANDARDS IS:2190 CLASSIFIES THE FIRE IN FOUR CATEGORIES ACCORDING TO THE TYPE OF MATERIAL BURNING.

CLASS A ; FIRES INVOLVING ORDINARY COMBUSTIBLE MATERIAL LIKE WOOD, PAPER, TEXTILES ETC. WHERE THE COOLING EFFECT OF WATER IS ESSENTIAL FOR EXTINGUISHMENTS OF FIRE.

EXTINGUISHING MEDIA-WATER

CLASS B : FIRES IN FLAMMABLE LIQUIDS LIKE OILS, SOLVENTS, PETROLEUM PRODUCTS, PAINTS ETC. WHERE A BLANKETING EFFECT IS ESSENTIAL TO EXTINGUISH THE FIRE.

EXTINGUISHING MEDIA-FOAM, CARBON DIOXIDE, DRY CHEMICAL POWDER.

CLASS C: FIRES INVOLVING GASES OR LIQUEFIED GASES IN THE FORM OF A LIQUID SPILLAGE, OR A LIQUID OR GAS LEAK. HERE IT IS NECESSARY TO DILUTE THE BURNING GAS AT A VERY FAST RATE WITH AN INERT GAS OR POWDER.

EXTINGUISHING MEDIA - CARBON DIOXIDE, DRY CHEMICAL POWDER. THE BEST WAY TO EXTINGUISH SUCH FIRES IS BY STOPPING THE FLOW OF FUEL GAS TO FIRE. CONTAINER IS KEPT COOL WITH WATER SPRAY.

CLASSIFICATION OF FIRE

CLASS D : FIRES INVOLVING METALS LIKE MAGNESIUM,

ALUMINUM, ZINC, POTASSIUM ETC. WHERE THE BURNING METAL

IS REACTIVE TO WATER AND WHICH REQUIRE SPECIAL

EXTINGUISHING MEDIA.

EXTINGUISHING MEDIA- SPECIAL DRY POWDER.

ELECTRICAL FIRE : ELECTRICAL FIRES ARE NOT TREATED AS A

CLASS OF THEIR OWN, SINCE ANY FIRE INVOLVING, OR STARTED

BY, ELECTRICAL EQUIPMENT MUST, IN FACT, FALL INTO ONE OF

THE OTHER CATEGORIES.

THE NORMAL PROCEDURE FOR DEALING WITH AN ELECTRICAL

FIRE IS TO CUT OFF ELECTRICITY AND USE AN EXTINGUISHING

MEDIA APPROPRIATE TO WHAT IS BURNING.

FLAMING AND/ OR SURFACE (GLOW)

RADIATIVE FEEDBACK

INTERFACE

SOLID

UNINHIBITED CHAIN REACTION

CONTINUOUS REIGNITION

DIFFUSION

VAPOUR

RADIATIVE FEEDBACK

SOLID LIQUID

GAS

OXYGEN

PYROLYTIC DISTILLATION

VAPORISATION

ON INPUT ENERGY REQUIRED

AND/OR

SOURCE OF IGNITION

INITIAL RELEASE OF ENERGY TO TRIGGER COMBUSTION (FIRE). IT IS NECESSARY TO UNDERSTAND THE SOURCES OF IGNITION AND TO ELIMINATE THEM TO PREVENT FIRES/EXPLOSIONS IN OUR REFINERY.SOURCES OF IGNITION

EXAMPLE PREVENTIVE MEASURES

ELECTRICAL EQUIPMENT

SPARKS FROM MOTORS, SWITCHES, LAMPS, HOT ELEMENTS AND ELECTRICAL DEFECTS

1. USE OF APPROVED EQUIPMENT

2. FOLLOW NATION ELECTRICAL CODES

3. PROPER MAINT.

FRICTION HOT BEARINGS, MIS-ALLIGNED OR BROKEN M/C PARTS, CHOCKING, JAMMING OF MATERIAL, POOR ADJUSTMENT

PREVENTIVE MAINT. AND PROPER LUBRICATION

OPEN FLAMES CUTTING AND WELDING TORCHES GAS & OIL BURNERS

STRICT COMPLIANCE OF PRECAUTIONS STIPULATED IN THE FIRE PERMIT FOR HOT JOBS.

SOURCE OF IGNITION

SOURCES OF IGNITION

EXAMPLE PREVENTIVE MEASURES

SMOKING AS IGNITION

SMOKING BOOTHS IN AREA WHERE COMBUSTIBLE ARE USED

1. SMOKING ONLY IN AREAS PERMITTED.

2. USE OF PRESCRIBED RECEPTACLES FOR CIGARETTE BUTTS

SPONTANEOUS IGNITION

PYROPHORIC IRON, HOT OIL LEAKAGE

1. KEEP PYROPHORIC IRON WET ARE THE TIME WHEN IT IS TAKEN OUT.

HOT SURFACES CONTACT OF COMBUSTIBLE MATERIAL WITHOUT SURFACES, HEATED LINES

1. PROVIDE PROPER INSULATION AND AIR CIRCULATION.

SPARK FROM ENGHINE EXHAUST

POL TRUCKS / DG SET 1. SPARK ARRESTOR ON EXHAUST

SOURCE OF IGNITION

SOURCES OF IGNITION

EXAMPLE PREVENTIVE MEASURES

STATIC ELECTRICITY

DURING SPLASH LOADING AND LOADING AT HIGH VELOCITIES

1. PROPER EARTHING OF EQUIPMENT.

2. DO NOT RESORT TO SPLASH LOADING

3. LOADING VELOCITY SHOULD BE CONTROLLED

LIGHTENING THUNDERSTORM CLOUD BURST

1. PROPER LIGHTING ARRESTOR AND EARTH CONTINUITY.

DETECTING & FIGHTING FIRE

FIRE

DETECTION WARNING ESCAPE

FIRE BRIGADE

IMMEDIATE ATTACK

Latest Trends in First Aid Fire Latest Trends in First Aid Fire ExtinguishersExtinguishers

MAJOR REFINERY POTENTIAL HAZARDS

• FIRE HAZARD

• EXPLOSION HAZARD

• ELECTRICAL HAZARD

• TOXIC GAS RELEASE HAZARD

• HAZARDOUS CHEMICAL HAZARD

• OIL SPILLAGE

• RADIATION HAZARD

• FALL FROM HEIGHT

Pump Fires Flange Fires Equipment / piping insulation Fire Ducts and cable Fires Storage tank Fires Pool Fire Jet Fire BLEVE UVCE Toxic Gas Release Oil spillage Flood

Types of Emergencies in Refinery

Fire Control

CompartmentationFire compartments are generally included in

building design to limit fire and smoke spread .

Fire Contained Within Compartment Cell

Smoke

Fire Resistance Wall

Fire Resistance Door

Fire Resisting Floor

Compartmentation

Factors Affecting Compartmentation: Occupancy Load Building type or purpose Fire load Height Active Fire Systems

Compartment walls and floors are constructed to separate areas in a building with different uses, and to reduce the maximum likely size of fire. This places a limit on the Quantity of materials which can be consumed by a Fire.

Exit from each Compartment to Stair case, lifts or Escape Route must have equivalent level of fire resistance.

Structural Fire Protection

Key Objectives are:

• Controlling Spread of Fire through Compartmentation.

• Preventing Structural Collapse for a period of time for Escape , Active Fire systems detection and activation or External help such as Fire Brigade to arrive

• Maintain the Integrity and Insulation of Structural Components to prevent Heat and smoke from Reaching Occupants.

•Prevent Disproportionate Damage to Property.

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Fire Detection Systems

With the introduction of the micro-chip, address technology took a giant step.

1980’s Circuit 1990’s Micro-Processor Technology Technology

Typical Addressable Detection Loop

PS2/CMXPS2/CMX

SPRINKLER FLOWSPRINKLER FLOWINPUTSINPUTS

ISOLATORISOLATOR

DOOR DOOR CONTROLSCONTROLS

ISOLATORISOLATOR

32

Elements of Fires Every fire gives different elements to be sensed

SMOKE Dark or light ?

HEAT Fixed or ROR ?

LIGHT UV – IR ?

GAS CO – CO²

Every technology has its disadvantages

33

Components

A true multi criteria detector that can smell, feel, and see its environment with intelligence using 4 sensing technologies

-CO sensor-Photo sensor-Thermal sensor-IR light sensor-Time & logic functions

34

What is Aspirating Smoke Detection? A system which draws air from an area, via a

pipe network, to a central detector which monitors for small amounts of smoke

Sampling pipeSampling pipe

VESDALaserPLUS 88

FIRE PROTECTION

OBJECTIVE : TO CONTAIN THE SPREAD OF FIRE

TYPES:

• ACTIVE FIRE PROTECTION SYSTEM

• PASSIVE FIRE PROTECTION SYSTEM

FIRE PROTECTION

FOLLOWING FIRE PROTECTION FACILITIES SHALL BE PROVIDED

DEPENDING ON THE NATURE OF THE INSTALLATION AND RISK

INVOLVED:

• FIRE WATER SYSTEM

• FOAM SYSTEM

• CLEAN AGENT SYSTEM

• CO2 SYSTEM

• DCP EXTINGUISHING SYSTEM

• DETECTION AND ALARM SYSTEM

• COMMUNICATION SYSTEM

PASSIVE FIRE PROTECTION SYSTEM

•DYKE WALLS

• SAFETY VALVES ON EQUIPMENT

• WATER SEAL IN SEPARATORS

• RUPTURE DISC IN PROCESS PIPING

• FIRE PROOFING OF STRUCTURES

• FIRE RETADANTS PAINTS ON CABLES

• FIRE BARRIERS

• POSITIVE PRESSURIZATION

• FLARING / VENTING

FIRE FIGHTING

OBJECTIVE : TO EXTINGUISH THE FIRE WITH MINIMUM LOSS

IT IS THE LAST LINE OF THE DEFENSE. IT COMES INTO FORCE WHEN

THERE IS ACTUAL FIRE. MAIN PURPOSE IS TO EXTINGUISH THE FIRE

WITH SUITABLE EQUIPMENT AND MATERIALS WITH AN AIM TO

REDUCE DAMAGE DUE TO FIRE

• PORTABLE FIRE FIGHTING EQUIPMENT

• MOBILE FIRE FIGHTING EQUIPMENT

• FIXED FIRE FIGHTING SYSTEM

FIRE FIGHTING S. NO.

TYPE OF FIRE RISK

EXAMPLE OF OCCUPANCIES

SCALE OF EQUIPMENT

1 A) CLASS ‘A’ LIGHT HAZARD

OFFICES (OTHER THEN RECORD ROOM) SCHOOL CLUBS, ETC.

FOR EVERY 600 M2 FLOOR AREA 1 NO. 9L WATER TYPE, MAX. DISTANCE 25 M

B) CLASS ‘A’ ORDINARY HAZARD

ORDINARY RECORD ROOM TAILORING SHOP. BOOK BINDER ETC.

FOR EVERY 600 M2 FLOOR AREA 2 NOS. 9L WATER TYPE MAX. DISTANCE 15 M

C) CLASS ‘A’ EXTRA HAZARD

LARGE TIMBER YARDS SAW MILLS HOUSE OF COMBUSTIBLE MATERIALS

‘DO’ + SOME EXTRA PROVISION AS PER LOCAL AUTHORITY.

D) CLASS ’A’ SPECIAL HAZARD

IMPORTANT OFFICE RECORDS, LIBRARIES DATA PROCESSING

FOR EVERY 100 M2 1 NO. 4.5 KG CO2. MAX.

DISTANCE -10 M

2 A) CLASS ‘B’ SMALL QUANTITY HANDLED

WORKSHOP. GARAGE ETC.

2 NOS. FOAM / DCP PER 50 M2 AREA. MAX. DISTANCE – 10 M

FIRE FIGHTING

S. NO.

TYPE OF FIRE RISK

EXAMPLE OF OCCUPANCIES

SCALE OF EQUIPMENT

B) CLASS ‘B’ BULK STORAGE OTHER THEN TANK FARMS

FLAMMABLE LIQUIDS IN CAN, DRUMS ETC.

3 NOS. FOAM /DCP PER 100 M2 AREA. MAX. DISTANCE – 10 M

3. CLASS ‘C’ HANDLING /STORAGE OF GAS CYLINDERS, GAS PLANT ETC.

2 NOS. DCP/CO2 (6.8 kg)

PER 200 M2 AREA. MAX. DISTANCE – 10 M.

4.. CLASS ‘D’ REACTIVE METAL STORAGE

2 NOS. DCP PER 50 M2 AREA. MAX. DISTANCE – 10 M.

5. MIXED OCCUPANCY (ELEC. RISK)

W/SHOP, X-MERS MOTORS, TEL, EXCH., ETC.

1 NO. DCP/CO2 PER

100M2 AREA.

  

SOME DO’S & DON’T’S IN EMERGENCY SITUATIONS

(GENERAL GUIDELINES

DO’S: KEEP COOL, DON’T BE PANIC. IF ANY GAS LEAKAGE IS REPORTED ,MOVE ACROSS

THE WIND TO A SAFE PLACE KEEP WET CLOTH ON THE NOSE AND BREATH

NORMALLY IMMEDIATELY EXTINGUISH THE FIRE IN SIGRI, CHULLAH

OR BHATTI WITH WATER IN & AROUND THE HOUSE.

Igniting Minds... Energizing Lives…

Haldia Refinery

  

SOME DO’S & DONT’S IN EMERGENCY SITUATIONS

(GENERAL GUIDELINESDO’S:IMMEDIATELY PUT OFF ANY OPEN FLAME LIKE CANDLE,

LANTERN, HEATER ETC. IF EVACUATION IS CALLED FOR, LOCK THE HOUSE

AND BE READY FREE DOMESTIC ANIMALS. HELP FIRE FIGHTING TEAM AND EMERGENCY STAFF

TO KEEP THE SITUATION UNDER CONTROL. LISTEN CAREFULLY THE ANNUOUNCEMENT IN YOUR

AREA AND FOLLOW THE INSTRUCTIONS.

Igniting Minds... Energizing Lives…Haldia Refinery

  

SOME DO’S & DON’T’S IN EMERGENCY SITUATIONS

(GENERAL GUIDELINES

DONT’S: DONOT PUT ‘ON’ OR ‘OFF’ ANY ELECTRIC SWITCH. IF ANY

ELECTRIC SWITCH IS ‘ON’ KEEP IT’ON’ POSITION ONLY. DONOT SMOKE AND DO NOT ALLOW ANYBODY TO

SMOKE. DONOT PAY ATTENTION TOWARDS RUMORS AND DO

NOT SPREAD ANY RUMOR ALSO. DONOT BLOCK ANY PUBLIC AREA DONOT USE ANY PERSONAL VEHICLE DURING ANY EMERGENCY SITUATION DONOT

UNNECESSARILY TALK ON PHONE.

Igniting Minds... Energizing Lives…

Haldia Refinery

Know your fire safety rules by heart, More importantly, practice them:

1. Have a written down Fire Prevention Plan for your Company, and ensure that it is sincerely implemented.

2. Identify and eliminate fire risks or reduce them to the maximum extent possible.

3. Train and retrain your employees in fire prevention and fire fighting.

4. Install suitable fire protection equipment and make sure that your employees know how to use it in case of fire.

5. Regularly inspect your fire safety equipment so that it does not fail in an emergency. Have adequate water supply.

6. Establish an Emergency Plan in close coordination with the public fire department.

Fire Safety ChecklistFire Safety Checklist

7. Take the utmost care while handling flammable materials. Provide special protection for major fire risks.

8. Follow good housekeeping practices, because a clean house is a safe house.

9. Protect the workplace hazards within and outside by having suitable construction.

10. Never violate fire safety laws – they are meant for your protection.

Thank you for your attention.

Any Questions ??