Project On Fire

OCCUPATIONAL HEALTH & SAFETY ASSESSMENT. Terms Used: 1. HAZARD

:

Potential to cause injury, damage to Environment, Health and Property.

2. RISK

:

combination of the likelihood and Consequences of a specified Hazardous event occurring.

3. LOSS

:

It is an avoidable waste of any resource.

4 INCIDENT

:

It is an event giving rise to an accident or had the potential to lead to an accident.

5. NEAR MISS

:

An unattended occurrence which may not result in an Injury or Damage (eg. Elec. Shock, Gas leak, Oil Spill, Process upset.)

6. ACCIDENT

:

It is an undesired event-giving rise to death, ill health, injury,Damage or any other loses.

7. SAFETY

: It is about managing the risk and to control the accidental risk.

8. OH & S RISK MANAGEMENT: The essence of the Risk Management is to avoid High Risks, Manage Medium Risks and Live with Low Risks.

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OCCUPATIONAL HEALTH HAZARDS: CHEMICALS: •

Dust / Fiber.

•

Smoke.

•

Aerosols.

•

Gases / Vapors.

PHYSICAL: •

Noise.

•

Vibration.

•

Pressure.

•

Temperature.

•

Radiation.

•

Illumination.

BIOLOGICAL: •

Virus.

•

Bacteria.

•

Fungi.

ERGONOMIC: •

Lifting.

•

Repetitive motion.

•

Monotony.

•

Fatigue.

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OCCUPATIONAL HEALTH & SAFETY ASSESSMENT: Will help the Organization to formulate Occupation Health and Safety Policies and Objectives in accordance with legislative requirements and identified Occupational Health and Safety hazards and associated Risk assessments. These requirements shall be implemented by the Organization and is dedicated to save Life, Property and Environment.

RELATIONSHIP BETWEEN OCCUPATION & HEALTH: Occupational diseases are those, which may arise out of or in the course of employment.The state of health of the worker can influence his ability to work Safely and Efficiently. The environmental factors, such as: presence of Contaminants in the air, Physical factors like heat, humidity, noise, radiation, etc. have effect on the state of workers health. Workers are at risk of getting exposed to toxic agents. It is therefore, is important that the employees are to be kept in healthy state. MODE OF ACTION OF A HAZARD: The main entries of toxic substances into human body are: •

Inhalation.

•

Skin absorption.

•

Ingestion.

PREVENTION: Satisfactory maintenance, Good House Keeping, Education of the employees and proper Personal Hygiene are the four items, which help in the prevention of worker’s occupational illness.

4

OCCUPATIONAL HEALTH LEGISLATION FOR PROTECTION OF WORKER’S HEALTH. (ILO). has developed instruments such as: Hours of work. Night work. Weekly rest. Paid leave. Guide line of workers health protection. Improvements in working conditions. Protection against Specific Risks. (Handling of Toxic materials, Lifting & carrying of heavy loads,) Air Pollution, Noise, & Vibration. INDUSTRIAL INJURY: Industrial injury or accident means any Organic disturbance whether immediate or subsequent or Death, occurring suddenly in the course of the employment or in consequence thereof, irrespective of the place or time where it occurs. Injuries may be: •

Temporary incapacity.

•

Permanent Partial Incapacity.

•

Permanent Total Incapacity.

•

Death.

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FIRE TRIANGLE OR PYRAMID Three conditions have long been regarded as essential components of any fire : 1. Fuel (i.e. the combustible material). 2. Oxygen (from the atmosphere). 3. Heat (essential to start the fire initially, but maintained bye the fire itself once it has started).

These are familiar to fire fighters as the ‘fire triangle’ or pyramid. If any one of these conditions is removed, the fire goes out. Methods of fire fighting thus depend on removing or shutting off the source of fuel, excluding oxygen or removing heat from the fire faster than it is liberated. A fourth condition is now recognised. Flames proceed chemically as branched chain reactions through the intermediary of free radicals which are constantly being formed and consumed. If the free radicals can be removed and prevented from continuing the chain reaction, the flame goes out. Various chemicals used in dry powder and halogenated hydrocarbon extinguishers capture free radicals and put out the fire in this way. Potassium bicarbonate is more effective than sodium bicarbonate and free halogen radicals, especially bromine formed when a brominated hydrocarbon meets a fire, are also effective. Thus the familiar fire triangle becomes a pyramid and now includes the fourth condition.

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FIRE PROTECTION IN PETROCHEMICAL INDUSTRY From the above one car well imagine the potential fire risks in a petrochemical industry. The fire protection can be divided into three phases :

i.

i.

By good plant, design and layout

ii.

Fire control – keeping the fires localised

iii.

Fire extinguishment

Plant Design & Layout : A good plant, design and layout, with strict adherence to safe operating procedures, proper built-in fire prevention system, fire-fighting training and adequate emergency plan to meet fire emergencies, is the best way to minimise the possibility of fire damages. Factors to be considered for the plant layout include adequate spacing and proper arrangement of various utilities, process units, storage units and vessels, loading and filling installations. For plant layout, safety rules laid down in the petroleum act should be followed.

ii.

Fire Control : This embodies protection of tanks, pressure vessels, structures, pipelines and equipment that are effected by direct flame impingement or by radiate heat exposure. Cooling prevents the spread of fire from its point of origin to the surrounding areas.

iii.

Fire Extinguishers : After adequate fire control measures fire is extinguished by employing suitable extinguishing media, like water, foam, dry chemical powder, Co2, Halogenated vapourising .

Storage Tanks In a petrochemical complex, storage tanks of various types of storing the raw materials like Naptha, and Zylene as also the other products are required. These materials being highly inflammable adequate fire protection, fire prevention and fire-fighting arrangements are very essential. In case of any fire emergency, there must be arrangement to cool the tanks which is involved and the surroundingones. Arrangements for fighting the fire is also necessary, while planning the fire protection arrangement, it should worked out on the basis of meeting a major fire indicants. Among the extinguishing media water is employed extensively for cooling and foam generation. The maximum water flow rate is determines by taking into consideration the possibility of following simultaneous operations. 7

i.

Water for foam generation.

ii.

Water for cooling.

i.

Water for foam generation : As per N.F.P.A. Handbook and code and American Institute Standard for petroleum refineries, water for foam generation for fixed foam pourers should be provided not less than 4.03 L/min for each IM2 of the liquid surface area. For hose streams, at least 6.5 Lit/min of water should be provided. In case of liquid hydrocarbon a delivery rate of 300 liters of foam/m 2 of burning area is specified for a minimum period of 10 min.

ii.

Water for cooling : In a fire emergency the tanks which are on fire to be cooled as also the adjoining tanks are to be protected from exposure. For these purposes a flow rate of 10.2 L/min to 20.4 L/min per m2 and 8.16 L/min – 10.2 L/min respectively is considered satisfactory.

Water Storage Adequate water storage is one of the most essential requirement of fire-fighting system. The total capacity of water storage as usually based on 4-10 Hrs. duration of firefighting. Provision storage tanks. The fire water storage tanks should be so placed that water can be delivered under gravity in case of failure of all pumps.

Fire Water Supply System Water supply arrangement should be designed for a reliable and adequate supply of water under pressure (7 kg/cm2) for fire-fighting at each strategic point. This is generally measured by laying independent fire water mains of appropriated diameter along plant roads and access codes in block system. The main network is arranged in such a way that each area is surrounded by mains and sub-headers. Block valves, on the ring main, for maintenance purpose are placed at suitable intervals in such a way that they always ensure sufficient water supply for the operation of fire-fighting appliances.

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Fixed Installations i.

Fire Hydrant : Hydrants are to be placed at suitable intervals on fire water mains. Normal distance between the hydrants is 45 m to 90 m depending upon layout of area, water requirement. Discharge from each hydrant should be 1125 l/min at a high pressure.

ii.

Hose Reels : For immediate availability of water in process area permanently connected hose-reels are used extensively. These reels should be provided with 40 mm bore hose of 30 m length.

iii.

Monitors (For Water/Foam) : Fixed monitors are preferred for spot use. Because of limited area coverage from these monitors careful consideration has to be given in locating the same to ensure maximum effectiveness. Water stream, water spray/jet could be applied through the monitors by using co9mbination nozzles.

Water Spray System Water spray cooling system are usually provided to minimise fire exposure. Manual / automatic/ remote controlled water spray is practically useful for cooling uninsulated steel structures elevated pipes, vessels, spheres etc.

Water Fog System Water fog systems are intended to reduce fire intensity by mixing of water with fuel vapour or by the contact of fire drops or a very fine mist of water with oil surface. Water fog is effective on viscus oil or high flash point oils, where areas are within the range of fog nozzles. However, except under ideal conditions, it is seldom effective for extinguishment of fires in gasoline or other low flash point products. Pumps handling, hydrocarbon, compressors control valve, main folds, columns, and other

9

vessels under high temperature and pressure are protected with water fog systems. These systems can be either manual or automatic.

Portable Fire Extinguishers Since in a petrochemical industry most of the fire encountered are that of liquid hydrocarbon, or vapours, portable extinguishers such as foam, dry powder, Co2 in adequate numbers are to be provided at strategic points to tackle a fire at its incipient stage.

Carbon Dioxide And Other Inert Gases These systems must be used with great caution indoors when people are present, due to their asphyxiating action in lowering the oxygen content of the air. In at least one case a man fighting a fire in a basement with carbon dioxide extinguishers which were handed down to him from above collapsed and died as a result of oxygen deficiency in the atmosphere.

Gas extinguishing systems consist of a supply of the inert gas under pressure (usually in cylinders), a system of pipework and valves delivering the inert gas to the points of application and an automatic detection and initiating system which opens inert gas valves once the fire has been detected. It also, in many cases, closes doors and ventilation ducts. These systems operate by reducing the oxygen content of the atmosphere and/or by interrupting the chemical reaction in a flame.

Most of the gases used are suitable for electrical equipment and plants handling flammable liquids. This system is particularly suitable for protecting valuable equipment which is easily damaged by water and foam, such as computers. For these systems to operate most effectively, the fire fighting equipment should be housed in a gas-tight compartment which is closed to the atmosphere when a fire starts. Carbon dioxide installations need special care to avoid introducing risks of ignition by static electricity.

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Dry Powder Dry powder is a term used for various free-flowing powders which when poured or otherwise discharged over a fire will extinguish it. The compositions of many fire extinguishing powders are not publicised by their makers for obvious reasons. They generally contain three principal ingredients each with a particular function.

1. Sodium or potassium bicarbonae. These liberate carbon dioxide when heated. Bicarbonates are thus a convenient means of applying carbon dioxide. They also react with and neutralise acids and some other reactive compounds and prevent damage from acids released by a fire. Potassium bicarbonate is claimed to be more effective than sodium bicarbonate due to its greater chain terminating effect. 2. Certain finely powdered salts of metals which when present as a dust in the atmosphere strongly absorb radiant heat, thereby cooling and in some cases extinguishing flames. 3. A compound which prevents the powder particulars from adhering to one another and forming lumps, thus preserving the free-flowing properties of the powder. Dry powder installations comprise dry powder container to which a gas cylinder (usually carbon dioxide) is coupled, and a system of piping and outlets which are located above the places where fires are likely to break out. They can be operated automatically or manually by opening valve on the gas cylinder so that the gas drives the powder to the outlets.

These installations are suitable for flammable liquids and electrical equipment and for protecting some processes involving solids which are easily damaged by water or foam.

Portable Appliances Portable fire extinguishers may be used to deliver water, dry powder, foam, carbon dioxide or a vapourising liquid to the seat of a fire. Their use should, as far as 11

possible, be standardised and the minimum number of types necessary should be carried. Hose reels are generally preferable. Supervisors should be abel to identify the different classes of fires and should know which type of portable extinguisher to use. All personnel should know how to recongnise and use the various types of extinguishers present. Practice sessions should be set up to ensure that all personnel act promptly and effectively in dealing with small fires.

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Portable Water Discharging Extinguishers Extinguishers which deliver water operate in various ways: a. The water bucket. This is the simplest of all; it must, however, be kept full of clean water and always in the place reserved for it. Some skill is required in directing the contents of a water bucket onto a fire probably more so than closed portable extinguishers with nozzles. b. Gas pressure applied from a cartridge. A small cartridge of liquefied carbon dioxide is held inside the top of the cylindrical extinguisher. The cartridge has a brass cap which is pierced by a plunger passing through a gland in the top of the extinguisher. This is actuated by a sharp blow by the hand to the top of the plunger. Gas released in the extinguisher drives the water out through a discharge tube which extends to the bottom of the cylinder and is connected outside the cylinder to a nozzle via a short length of flexible hose. c. Stored gas pressure. The whole extinguisher is pressurised with gas at the time of charging with water. Water is discharged by opening a valve on the discharge tube. d. Gas pressure formed by reaction between an acid and a carbonate within the extinguisher. The extinguisher has an inner container filled with an acid solution (generally aluminum sulphate). The main body or outer container of the extinguisher is filled with a solution of sodium bicarbonate. The contents of the inner cylinder are released into the outer cylinder by inverting the cylinder and releasing a spring operated plunger. When the solutions mix, gas is formed which pressureises the extinguisher. A jet of water issues through a nozzle on the upper part of the extinguisher, so ling as the extinguisher remains inverted. The flow of water stops when the extinguisher is turned the ritht way up and surplus gas escapes. e. Hand pump inside the cylinder. This is operated by a handle extending through a gland in the top of the cylinder. The applications and limitations of water extinguishers have already been discussed. Water is best used for fires on solid materials which may re-ignite if not adequately cooled. It can readily penetrate to reach a deep seated fire. when using a water-filled extinguisher, direct the jet at the base of the flame and keep it moving across the area of fire. a fire moving vertically should be attacked at 13

its lowest point and followed up. seek out any hot spots after the main fire is extinguished.

Portable Foam Extinguishers Foam extinguishers are of two types, mechanical and chemical. These correspond to water extinguishers in which the pressure is derived from a gas cartridge and from chemical reaction respectively. But the chemical foam extinguisher, unlike the soda-acid type of water extinguisher, is used in the normal upright position. Portable foam extinguishers have a capacity from 4 to 10 liters and a range of about 7 m. 10 liters for foam are normally required to extinguish 1 m2 of burning liquid. When a liquid fire has been extinguished by foam, the foam blanket left over the liquid remains in position thus preventing re-ignition and allowing the liquid to cool. Foam extinguishers should therefore be used for liquid fires where the liquid has been burning for some time and has become hot. Foam is not effective on flowing liquids, whether the flow is horizontal or vertical. Foam conducts electricity and should not be used on live electrical fires. Most water miscible liquids break up ordinary foams. When a liquid on fire is in a container, direct the jet at the far inside edge of the container, or at an adjoining vertical surface above the level of the burning liquid. This breaks up the jet and allows the foam to build up and flow across the surface of the liquid. When this is not possible, stand well back and direct the jet slightly upward so that the foam falls on to the surface of the liquid. Move the jet gently from side to side to cover the surface of the liquid. Do not direct the jet into the liquid because this will dive the foam beneath the surface and render it ineffective. It may also splash the burning liquid on to surrounding objects.

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Portable Dry Powder Extinguishers The use and composition of dry powder have already been discussed under fixed installations. Portable dry powder extinguishers are made with capacities from 2 to 10 kg of powder. In operation and appearance they are like water extinguishers where the pressure is supplied from a gas cartridge. Their range is less than a water extinguisher, usually from 3-6 m.

These are the best type of extinguisher for dealing with fires of flammable liquids. They extinguish the flames over the liquid and thus act faster than foam. They can deal with larger areas of burning liquid than other extinguishers of the same size, and they are effective on fires of flowing liquid. Dry powder can be safely used on electric fires. The main limitation of dry powder is that it gives no protetion against re-ignition after application ceases since it has poor quenching properties. It is less effective than foam on liquid fires where the liquid has become overheated (i.e. through prolonged burning). Two kilograms of dry powder can normally extinguish a liquid fire converting and area of one square meter when properly applied.

Portable Carbon Dioxide Extinguishers Carbon dioxide extinguishers should only be used sparingly in buildings due to the dangers of asphyxiating personnel. A second hazard of carbon dioxide extinguishers is the formation of static electricity in the discharge which can ignite flammable vapours, sometimes with fatal consequences.

15

Carbon dioxide acts more rapidly than foam and is more suitable for dealing with fires which might spread to surrounding materials before a complete foam blanket could be formed over the burning liquid. Carbon dioxide extinguishers are suitable for dealing with small fires of liquids flowing over horizontal and vertical surfaces. They should be used where the main concern is to avoid damage or contamination by dry powder deposit or foam, for example to laboratory equipment or food preparation.

The cooling properties of carbon dioxide are limited and it gives no protraction against re-ignition after application ceases. It is less effective that foam for very hot liquids burning in containers.

Carbon dioxide extinguishers contain the carbon dioxide and high pressure as a liquid in steel cylinders, with a valve leading via flexible hose to a horn shaped discharge tube. These extinguishers are normally used with the valve uppermost so that carbon dioxide is discharged as a gas. If they are inverted, a mixture resembling snow of carbon dioxide gas and solid carbon dioxide is discharged, provided the extinguisher is full and the ambient temperature is not excessive. Portable carbon dioxide extinguishers have capacities ranging from 1 to 6 kg and a range from 1 to 3 m.

Portable Vapourising Liquid (Halon) Extinguishers Portable vapourising liquid extinguishers are now mainly restricted to the use of two compounds, bromochlorodifluoro methane or BCF, and bromotrifluoro methane or BTM.

These may be discharged either by gas cartridge (containing carbon dioxide) or by pressuring the container with nitrogen. They can be fitted with a control valve if desired, so that can be discharged in short bursts, but once the seal has been broken they should be emptied, recharged and resealed. Their main action is by excluding oxygen from the flames. Since they do not conduct electricity they can be sued on electrical fires.

16

They have less static electricity risk then carbon dioxide, but they present the same asphyxiation hazard. In addition there is some risk of forming toxic decomposition products when their vapours are in contact with very hot metal, although this risk is far less than with older types of vapourising extinguisher which contained carbon tetrachloride, methyl bromide and other compounds which are little used now because of the toxic problem.

These extinguishers have a range of up to 6 m and 1 liter of liquid is sufficient to extinguish flames over an area of one square meter of burning liquid. The methods of using dry powder, carbon dioxide and vapourizing liquid extinguishers are essentially the same.

On fires involving liquids, either in containers or on the ground, direct the jet or discharge horn towards the near edge of the fire and with a rapid sweeping motion drive the fire towards the far edge until all the flames are extinguished. On fires in falling liquids, direct the jet or horn at the base of the lames and sweep upwards.

When dealing with electrical equipment fires, first turn off the current. Then direct the jet or horn straight at the fire. When the equipment is enclosed, direct the jet or horn straight at the fire. When the equipment is enclosed, direct the jet or horn into any opening so that it penetrates the interior.

If the extinguisher has a control valve on the discharge, shut it when the fire appears to be extinguished, wait until the atmosphere clears and, if any flame is then visible, open the valve and discharge again.

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PRINCIPAL CAUSES OF ACCIDENTS When we look at the piramid it indicates that there is a dilution in safe practices leading to undesired incidents by way of creating unsafe acts and unsafe condition in the plant. These unsafe practices can be eliminated if we properly document all the incidents including near misses. This documentation will help others to understand and identify

the deficiency in the system

practices. This will help

and

the consequence of the unsafe

to avoid repetition of the same incident. The

documentation also helps in developing improvement in the safe practices (to make procedures user friendly).

1. Accident Review Report 2. Incident Report 3. Fire Report 4.1

Accident Report In general shift concerned supervisor will make the report and sent the report to the safety dept. through dept. head within 24 hrs. of the accident occurrence. Other than general shift hours shift incharge (plant incharge) will make the report and send to safety dept. before the relieving from his shift through proper channel.

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ACCIDENT REPORT FORMAT 1. Name of the injured : 2. Designation

:_________ Emp.No._______

3. Sex _______________M/F 4. Address

Age___________

: _____________________ _____________________

5. Date of injury_________ Time of Injury_______ 6. Did the injured return to :___________________ work after first aid, when? 7. Description of Accident (describe briefly)

:

a) Where (location) exactly: did the accident occur? b) What exactly was the injured doing at the time of accident?

:

c) Name of the machine or : part caused accident ? d) Kind of power used to : run the machine. Mech/Elec/Hand 8) Indicate below by 'X' whether in your opinion the accident is caused by : a) Physical causes i) Improper guarding? : ii) Defective equipment? : iii) Hazardous arrangement? : iv) Improper ventilation? : v) Improper dress or apparel? : vi) Any mechanical cause? : vii) Not listed? Describe briefly:

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b) Unsafe Acts: i) Operating without authority? : ii) Failure to secure or warn? : iii) Working at unsafe speed? : iv) Made safety device inoperative/ bypassed v) Used unsafe equipment or hands: instead of equipment? vi) Unsafe loading, placement? : vii) Worked on moving equipment? : viii) Took unsafe position? : ix) Teased, abused distracted etc?: x) Did not unsafe clothes or personal protective equipment? xi) Not listed? Describe briefly) c) Personal causes: (Indicate Yes (or) No i) Physical or in attention? : Yes/No ii) Lack of knowledge or skill? : Yes/No iii) Improper attitude? : Yes/No iv) Was he under the influence of : Yes/No drink/drug vi) Not listed? Describe briefly? : Yes/No 9) What steps are taken to prevent : _____________ similar accident? 10) What other steps do you suggest : _____________ to avoid same or similar accidents? 11) Name of the Supervisor to whom : _____________ the injured is responsible?

12) Name and designation of two : 1) _____________ witnesses. _____________ 2) _____________ ------------Signature of the Dept.Head

Signature of the Engr.

Comments of the Safety Dept. or Review Committee

20

a) Cause of the accident:____________________________ b) Precautions suggested: 1) ________________________ 2) _______________________ 3) _______________________

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DETECTION AND COMMUNICATION SYSTEM COMBUSTIBLE GAS DETECTIVE SYSTEM APL has installed latest gas detection system all over the plant in the strategic areas. This helps to detect the

gas leaks and acts as an early warning system. Whenever

process gas leaks out from

the

process/storage system

and likely to build up

concentration to Lower Explosive Limit (LEL) in the atmosphere the detector system identifies any flammable gas or carbon monoxide and gives early alarm at 20% of the LEL or Threshold Limit value (TLV). If the gas continuous to leak and built up concentration second level alarm gives at 30% of the LEL. Immediately on receiving the first alarm on DCS (Digital control system) the location of the detector is identified and

further action will be taken. Whenever

carbon monoxide detector

actuates, the alarm is received on the DCS panel. It has two levels of alarm like in the case of combustible gas detectors. CARBON MONOXIDE GAS DETECTION: A total of 73 gas detectors were installed out of which 15 are meant for analysing carbonmonoxide gas. This is a special feature in APL which helps to detect gas leaks at early stage and suitable/prompt action will be taken. The action to be taken will be announced on paging system for quick communication between control room and various parts of the plant. This will help to identify any emergency at an early stage thus major disaster can be avoided. FIRE ALARM SYSTEM: The plant is provided with fire alarm system.

This consists of control panel with

audio visual indications at fire station and manual call points throughout the plant at strategic locations. Hooter provision was made in the control room and laboratory also. The emergency can be initiated by breaking the manual call point glass.

The

location is known to fire & safety dept. through the control panel. The hooter along with emergency siren is heard simultaneously at fire station, DCS and Laboratory.

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COMMUNICATION PROCEDURE: Person

who notices Fire will break the

Fire

alarm glass (or) Dial 333 (Fire

Station) EPABX or Use Public address system. The person giving the message should identify himself and give the message in short and clear about, Location Nature of Emergency Extent of damage After giving message he shall make an attempt to extinguish fire by using available appropriate extinguishers. As the Fire Engine comes to the site, guide it to the scene of fire emergency. Firemen will give the same message to DCS (333), Lab (427), Security (400). The DCS Control Room operator will receive the message and arrange to record the message on the board and report the same to the emergency controller. "EMERGENCY-NO ENTRY" Board will be displayed by the Security at the main gate. MODE OF COMMUNICATION Fire siren(both electrical & manual) Internal telephones Public addressing system Wakie – Takies P & T phones Hot lines facilities in between the mutual aid members Megaphone

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FIRE FIGHTING TECHNIQUES Fire extinguishment can be accomplished by four (4) methods. Smothering. Removing Oxygen supply; Foam, CO2, DCP, Steam, Water fog are applied on burning surface that cuts off Oxygen supply thus fire gets extinguished. In case of Tanker fires,closing the lid extinguishes fire. Starvation: This method is adopted when material leaking from a ruptured/leaky pipe. Closing or nipping the leaking pipe extinguishes fire due to starvation of fuel. NOTE: When fighting a pressurised gas/vapour fire, the personnel and equipment around should be protected by water spray.

While the fire is being extinguished by

starvation of fuel, if the fire is extinguished by other means a vapour/gas cloud will form, which may explode causing greater damage. Hence extinguishing fire is to be carefully timed.

The leaking systems should be purged with Nitrogen to prevent

ingress of Oxygen. Cooling: The burning fuel is cooled below ignition point, water spray or fog is the best cooling medium. Foam also cools the burning fuel while smothering. Note:-Water spray and foam should not be used simultaneously on fire. Neutralization of Chain reaction: Every fire involves a chain reaction,in which a multitude of chemical reactions generate chemical compounds or elements,that sustain the process.These elements are called "free radicals".Some means of extinguishing,such as powders,can scavenge these very reactive radicals,thus preventing propagation of the fire.These means have a negative catalytic effect on the fire. 24

DEFINITIONS EMERGENCY Emergency is defined as a situation in which an inflammable / toxic material is leaking into open atmosphere which might have caught Fire or may catch Fire at any moment. This is a potentially control

dangerous situation which is beyond the

of operating group and needs services of Fire Department and Others.

ON SITE EMERGENCY: If the emergency can be controlled with the available resources within the factory premises and does not spread outside the plant boundary it is termed as On- Site Emergency OFF SITE EMERGENCY: If the emergency becomes uncontrolled and leads to damage to life and damage property or environment within the factory and its neighbourhood community around the plant is termed as Off- Site Emergencywith the available resources within the factory premises and does not spread outside the plant boundary it is termed as On- Site Emergency NATURE OF EMERGENCY: Emergency as specified under this plan refers to occurrences of one or more of the following events. 1. Fire 2.

Release of toxic vapour/Flammable gases:

Release of toxic gas like carbon monoxide or flammable gas like Propylene, Purge Gas,Methane, Hydrogen which can cause Boiling liquid Expanding vapour Explosion (BLEVE) or vapour cloud explosion(VCE). CHIEF CO-ORDINATOR: C.E & C.O.O will be the Chief Coordinator. In the absence

of C.E & C.O.O ,

Senior Most person from Operations will be the Chief Co-ordinator.

25

EMERGENCY CONTROLLER: The Shift Chemical Engineer in-charge of the shift is designated as Emergency Controller. He will assume full responsibility of handling any emergency. He will wear red helmet in emergency for easy identification. FIRE ALARM (WAILING FIRE ALARM): Fire Emergency siren:-Sounding of Fire Siren intermittently at long. High peaks with short Low peak interval for a period of 1.5minute long. Evacuation siren:-3 times long high peak, 3 times short low peak siren. All clear siren:-Sounding of Fire Siren continuously for a period of 30 sec. to indicate that the emergency is over. FIRE PREVENTION FACILITIES Some of the fire prevention measures are as follows :

1.

Nitrogen blanketing provided to all storage tanks.

2.

Avoiding presence of free oxygen in the process

gases. 3.

Avoiding heat or spark

4.

Avoiding accumulation of static electricity.

5.

Connecting vapor lines of all equipment to flare

6.

Providing flame proof electrical equipment as per

hazardous zone classification. 7.

Providing lightening arrestors

8.

Providing gas detectors.

9.

Following effective P M schedules

10.

Following well established Safety systems.

11.

Employees training.

12.

Maintaining good house keeping.

26

13. 14.

Prevention of smoking. Prevention of cell phones

27

ABBREVIATIONS ACGIH

-

American Conference of Government Industrial Hygienists

CCOE

-

Chief Controller Of Explosives

ELCB

-

Earth Leakage Circuit Breaker

FLP

-

Flame Proof

PLT

-

Pipe Line Transfer

ILO

-

International Labor Organization

TAC

-

Tariff Advisory Committee

NDC

-

Non-Destructive Testing

PPE

-

Personal Protective Equipment

LPA

-

Loss Prevention Association

NEERI

-

National Environmental Engineering Research

MAH

-

Major Accident Hazard

LEL

-

Lower Explosive Limited

UEL

-

Upper Explosive Limit

IDLH

-

Immediately Dangerous to Life and Health

P&ID

-

Process and Instrumentation Diagram

PFD

-

Process Flow Diagram

UNICEF

-

United Nations International Children Emergency

IAEA

-

International Atomic Energy Agency

AGFFF

-

Aqueous Gel Film Forming Foam

AFFF

-

Aqueous Film Forming Foam

SHE

-

Safety, Health And Environment

BLEVE

-

Boiling Liquid Expanding Vapor Explosion

VCE

-

Vapor Cloud Explosion

OISD

-

Oil Industry Safety Directorate

ISRS

-

International Safety Rating System

DGFASLI

-

Directorate General Factory Advice Service & Labor

Institute

Fund

Institutes

28

CIMAH

-

Control of Industrial Major Accident Hazards

NSC

-

National Safety Council

MIC

-

Methyl Iso Cyanate

SCBA

-

Self Contained Breathing Apparatus

TREMCARD

-

Transport Emergency Card

CFC

-

Chloro Fluoro Carbons

UL

-

Underwriters Laboratories

HAZOP

-

Hazard and Operability Studies

BIS

-

Bureau of Indian Standards

ISO

-

International Organization for Standardization

WTO

-

World Trade Organization

ISO-9001

-

Quality Management Systems

ISO 14001

-

Environmental Management Systems.

PEL

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Permissible Exposure Limit

STEL

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Short Term Exposure Limit

TWA

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Time Weighted Average

TLV

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Threshold Limit Valve

MSDS

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Material Safety Data Sheet

COD

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Chemical Oxygen Demand

BOD

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Biological Oxygen Demand

APELL

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Awareness And Preparedness For Emergencies At Local Level

EIP

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Emergency Information Panel

OHSMS

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Occupational Health & Safety Management Systems

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BIBLIOGRAPHY

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Safety Magazines & Manuals

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Internet

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Safety Handbooks

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