Major Disasters

Fire Initiated Toxic Release

ANYTHING WITH POTENTIAL FOR PRODUCING AN ACCIDENT.

PROBABILITY OF HAZARD RESULTING AN

ACCIDENT.

HAZARD

RISK

Risk Management

Strategic Management

Operations Management

MAJOR FIRE RISK IDENTIFICATION

RISK ANALYSIS

TRANSACTIONAL DECISION YESNO

No Risk Management

Risk Control

Transfer Reduce Retain

For any Industrial Process Plant

Following questions must be asked and answered

1. What are the Hazards ?

2. What can go wrong and how?

3. What are the chances?

4. What are the consequences?

CONESQUENCES OF HAZARDOUS EVENT

•FIRE/ EXPLOSION

•VAPOUR CLOUD EXPLOSION

•FORMATION OF TOXIC ATMOSPHERE

Different Terminologies of Hazardous Situations

•Pool Fire

•Jet Fire

•Flash/ Cloud Fire

•Vapour Cloud Explosion (VCE)

•High Pressure Rupture

•BLEVE

•Release of Toxic Gases/ Liquids

Heat Radiation levels and Damage Effects

(As per API 521)

Radiation Level (kW/Sq.m)

Observed Effect

4.0 Sufficient to cause pain to personnel within 20 second

12.5 Minimum Energy required for piloted ignition of Wood and melting of Plastic Tubing

37.5 Sufficient to cause damage to Process Equipment

Explosion Over Pressure Level and Damage Effects

Overpressure (bar) Damage produced by Blast Effect

0.02 No considerable damage except shattering of few glass panes

0.13 Partial collapse of Buildings

0.20 Steel framed building distorted and pulled away from the foundation

THE FIRST STAGE OF RISK ASSESSMENT IN A PROCESS PLANT ESSENTIALLY CONSISTS OF THREE STEPS:

1. IDENTIFYING THE HAZARD

2. ESTIMATING THE EFFECTS OR CONSEQUENCES OF THE HAZARD

3. DETERMINING PROBABILITY OR LIKELIHOOD OF OCCURRENCE OF HAZARDOUS EVENT

THE NEXT STEP OF RISK ASSESSMENT

TO DETERMINE WHETHER EFFECTS OF THE CONSEQUENCE AND THE PROBABAILITY OF OCCURRENCE OF THE HAZARD IS WITHIN THE ACCEPTABLE LIMIT OR NOT.

HAZARD IDENTIFICATION METHODOLOGYHAZARDS IN PROCESS PLANTS ARE PRIMARILY IDENTIFIED BASED ON FOLLOWING INFORMATION:

•HAZARDOUS PROPERTIES OF MATERIALS

•TYPE OF UNIT PROCESS/ OPERATION

•OPERATING PARAMETERS

•ANY OTHER RELEVENT DATA

NFPA CODE NO. 325 M

CHECK-LIST

DOW INDEX

COMMONLY USED STRUCTURED HAZARD IDENTIFICATION TECHNIQUES

1. WHAT IF ? ANALYSIS:

• What if the Raw Material contains impurities?

• What if Cooling Water is Lost?

• What if the Vessel Agitation Stops?

• What if Power Supply Fails?

• What if the Temp./ Press. Sensor Fail?

• What if the Pump Stops? etc.

2. HAZOP STUDYGUIDE WORDS

• NO

• MORE

• LESS

• AS WELL AS

• PART OF

• REVERSE

• OTHER THAN, etc.

3. FAILURE MODE AND EFFECTS ANALYSIS (FMEA)

FMEA evaluates the ways in which an Equipment can Fail and the Effects of such Failures on an Installation

4. FAULT TREE ANALYSIS (FTA)

Deductive Reasoning Process

5. EVENT TREE ANALYSIS (ETA)

Inductive Process

RISK ACCEPTABILITY CRITERIA

Statistical Experience Shows•Chance of Death due to Risk of Driving, Flying or Smoking is 1 in 100000 or 10 –5

•Chance of Death from Lightning or Falling of Aircraft is around 10 –7 or 1 in 10000000

It is therefore generally accepted that the Risk of Death 1 in 100000 or 10 –5 per Year is Alarming.

Action needs to be taken to Reduce the Risk BELOW the level 1 in 1000000 or 10 –6 per Year and it is generally accepted without concern for Industrial People.

PROBABILITY ESTIMATION

Failure Rate data for Some Equipment

Equipment Failure Rate (Failures/ Year)

Process Pressure Vessel 2.7x 10 -3

Pressure Storage Vessel 1.8x 10 -3

Heat Exchangers 1.7x 10 -3

Fired Heaters 405x 10 –3

High Temperature vessel, except Fired Heater

7.4x 10 -3

Low Temperature Vessel 1.5x 10 -3

CONSEQUENCE ESTIMATIONSoftware Package Organisation

EFFECTS TNO, Netherlands

CISCOM CISRA, CLRI, CHENNAICHARM Radian CorporationPOOL FIRE/ BLEVE/ EXPLOSION Package

IIT, Kanpur

EAHAP Energy Analyst CorporationHASTE ERT Inc

SLAB Lawrence Livermore National LabTRACE Safer CorporationPHAST DNV TechnicaEx- TOOL Swiss Re

Public or Societal Risk

FN Curve for Societal Risk

Acceptable

Unacceptable

Reduction Desired

F.N. Lines

102 103

105

103

Nos. of Probable Fatalities N

Expected

Frequency

F

RISK CONTROL MEASURES

•Physical Protection

•Procedural Protection

•Educational Protection

Physical Protection•Strict & Rigorous approach in following the Relevant Standards , Codes & Practices

•Built in Safety Devices and Safety System

•Venting through Tall stacks

•Field Monitors for Different Toxic Gases

•Burning Waste gases in a Flare System

•Provision of Wind Cones

•Fire Proofing of Steel Structures

•PPE

•Passive Protection System

•Active Protection system

•Automatic Protection system

•Improved Waste Water Management

PROCEDURAL PROTECTION•Fire Emergency Procedure

•Disaster Preparedness Plan

•Mutual Aid Scheme

•No Smoking Policy

•Investigation of All Accidents

•Hazard Identification through Safety Committee, House Keeping Committee, Safety audit Committee

•Conducting Plant Survey, safety survey

•Work Permit System

•Statutory Requirement

•Safety Promotional Activities

Contd.

•Information notes on Unsafe conditions

•MSDS

•Annual Medical Check up of Employees

•Safe Start up & Shut Down Procedure

•Regular and Preventive Maintenance

•Periodic testing of Fire Fighting Appliances

EDUCATIONAL PROTECTION•Periodic Training Programme on Safety, Fire Safety and Hazardous properties of materials

•Mock Fire Drill

•Safety Manuals

•Health & Safety News Bulletins

•Safety Motivation schemes

•Plant Operating Manual

GROWING IMPORTANCE OF RISK MANAGEMENT DUE TO

•LEGISLATION

•CUSTOMER ATTITUDE

•SOCIETAL EXPECTATIONS

•MANAGEMENT ATTITUDES

The Science of Firevkx dk foKku

FIRE TRIANGLE

vfXu f=Hkqt

Hea

t rk

i@fp

axkj

hA

ir gok@vkD

lhtu

Fuel Toyu’khy inkFkZ

EXTINGUISHING MECHANISM

* STARVATION * SMOTHERING * COOLING

• It takes three things to cause a fire– Heat - something that is hot– Fuel - something that will burn– Oxygen - the air all around us

• If we take any one of these things away, the fire cannot survive

;fn ge fdlh ,d Hkqtk dks gVk nsxsa rks vkx cq> tk,xhA

vkx cq>kus ds rjhds

* Hkw[kk ekjuk * xyk ?kksVuk * BaMk djuk

Remember when we talked about the Fire Triangle?

• If you remove any one element, you prevent the chemical chain reaction that results from fire

• ;fn ge fdlh ,d Hkqtk dks gVk nsxsa rks psu fj,D’ku can gks tk,xk rFkk vkx cq> tk,xhA

Fuel - or something that will burn / Toyu’khy inkFkZ

Oxygen - or the air all around us

gok@vkDlhtu

• Removing Heat (Cooling/ BaMk djuk)– Control of

• smoking materials

• matches and lighters

• heating appliances

• candles

– Suppression• water cools a fire

And when we remove any one side of the triangle, like taking away the oxygen, the fire cannot survive

Fire Triangle • Removing Oxygen (Smothering/ xyk ?kksVuk)– Stop, drop and roll– Smothering action– Blanketing effect

• Removing Fuel (Starvation / Hkw[kk ekjuk)– Education messages

• good housekeeping practices

• storage of flammable liquids– in approved containers– away from heat sources

Hea

t

Oxygen/Air

FIRE TETRAHEDRON

FIRE EXTINGUISHING MECHANISM

STARVATION / Hkw[kk ekjuk SMOTHERING / xyk ?kksVuk COOLING / BaMk djuk CHAIN REACTION INHIBITION / psu fj,D’ku jksduk

FIRE EXTINGUISHING MEDIA

• WATER ikuh • CARBON DIOXIDE dkcZu Mkb vkDlkbM % lh- vks- Vw• DRY CHEMICAL POWDER MzkbZ dsfedy ikoMj • SAND jsr• FIRE FIGHTING FOAM Qkse vkx cq>kus dk• HALON ALTERNATIVES gSyksu ds le:i

Fire ClassesA Trash Wood Paper C Electrical Equipment / Flammable gas

B Liquids GreaseCOMBUSTIBLE

METALS

D

• Wood /ydMh• Cloth / diMk• Paper / dkxt• rubber• many plastics

• Gasoline / isVzksy

• Oil / rsy• grease

• tar

• oil-based paint

• lacquer

• energized electrical equipment fctyh ds midj.k

• flammable gases xSlsa• magnesium

• sodium

• potassium

• titanium

• zirconium

• other combustible metals /kkrq

Fire Classes (cont.)

K Cooking Media

• Recently recognized by NFPA 10.

• Fires involving combustible vegetable or animal non-saturated cooking fats in commercial cooking equipment. [kkus ds rsy esa vkx dks ,d vyx Js.kh nh xbZ gS ] ds Dykl Qk;jA

CLASS K FIRESCLASS K FIRES

CLASSES OF FIRE

1. CLASS “A” FIRE: - CARBONIOUS FIRE Toyu’khy Bksl oLrq EX.- WOOD, PAPER, COAL, PLASTIC, CLOTH, ETC EXTINGUISHING MEDIA: - WATER cq>k,a & ikuh ls

2. CLASS “B” FIRE: - FLAMMABLE LIQUID FIRE Toyu’khy nzo oLrq EX. – PETROLEUM PRODUCTS, GREASE, SOLVENT,PAINT, ETC EXTINGUISHING MEDIA: - FOAM, DCP cq>k,a & Qkse@MzkbZ dsfedy ikoMj ls

3. CLASS “C” FIRE: - INFLAMMABLE GAS FIRE / ELECTRICAL FIRE Toyu’khy xSls ,oa fctyh dh vkxA

EX. – LPG, METHANE, PROPANE, ACETYLENE, ETC EXTINGUISHING MEDIA: - DCP / CO2 cq>k,a & MzkbZ dsfedy ikoMj @lh-vks-

Vw ls

4. CLASS “D” FIRE: - METAL FIRE /kkrq dh vkx EX. – MAGNESIUM, ALLUMINIUM, ZINC, ETC EXTINGUISHING MEDIA: - SPECIAL DRY POWDER (TEC) cq>k,a & Lis’ky MzkbZ

dsfedy ikoMj ls

FIRE FIGHTING SYSTEM

1. FIXED FIRE FIGHTING SYSTEM• FIRE HYDRANT SYSTEM• FLOODING SYSTEM• MULSIFIRE SYSTEM• WATER SPRINKLER/ SPRAY SYSTEM• PORTABLE FIRE EXTINGUISHERS, ETC

2. MOBILE FIRE FIGHTING SYSTEM• FIRE TENDER• TRAILER PUMP, ETC

3. FIX-CUM- MOBILE FIRE FIGHTING SYSTEM• FOAM CHAMBER SYSTEM• FOAM POURER SYSTEM, ETC

PORTABLE FIRE EXTINGUISHERS fofHkUu izdkj ds NksVs vfXu’kked midj.k

1. WATER TYPE FIRE EXTINGUISHERS ikuh okyk vfXu’kked• CO2 CARTRIDGE TYPE• STORED PRESSURE

2. FOAM TYPE FIRE EXTINGUISHERS Qkse okyk vfXu’kked• MECHANICAL FOAM TYPE

3. DRY CHEMICAL POWDER TYPE MzkbZ dsfedy ikoMj okyk vfXu’kked

• CO2 CARTRIDGE TYPE• STORED PRESSURE TYPE

4. CARBON DIOXIDE TYPE FIRE EXTINGUISHERS lh-vks- Vw vfXu’kked

• STORED PRESSURE TYPE

WATER TYPE FIRE EXTINGUISHER ikuh okyk vfXu’kked

(STORED PRESSURE TYPE)SQUEEZE GRIPSAFETY CLIP/PINPRESSURE GAUGESIPHON TUBEPURE WATERDISCHARGE HOSE

NOZZLE

MECHANICAL FOAM FIRE EXTINGUISHER Qkse okyk vfXu’kked

PLUNGER

HANDLE

CO2 CARTRIDGE

FOAM MAKING

BRANCH

MECHANICAL FOAM FIRE EXTINGUISHER Qkse okyk vfXu’kked

(STORED PRESSURE TYPE)

SQUEEZE GRIPSAFETY CLIP/PINPRESSURE GAUGESIPHON TUBEDISCHARGE HOSEAFFF SOLUTION

FOAM MAKING BRANCH

DCP FIRE EXTINGUISHER MzkbZ dsfedy ikoMj okyk vfXu’kked

(CO2 GAS CARTRIDGE TYPE)

PLUNGERSAFETY PIN/CLIPCO2 CARTRIDGE PIERCER

CO2 CARTRIDGE

INNER CONTAINERDISCHARGE HOSESIPHON TUBEDCP

NOZZLE

CARBON-DI-OXIDE FIRE EXTINGUISHER lh-vks- Vw vfXu’kked

SAFETY PINWHEEL VALVE

HIGH PRESSURE DISCHARGE HOSE

CYLINDERHANDLE

DISCHARGE HORNSIPHON TUBELIQUEFIED CO2

Fire Emergency ResponseR RRescueescue

AAlarmlarm

CContainontain

EExtinguishxtinguish

A

C

E

Fighting the Fire

SSweep side to sideweep side to side

AAim low at the im low at the base of flamesbase of flames

SSqueeze thequeeze thehandlehandle

PPull the pinull the pinP

A

S

S

Flash point

• The flash point of a liquid fuel is the temperature at which vapour given off by fuel will ignite momentarily when an external flame is applied

• At flash point the liquid fuel vapour will not continue to burn

• Determines the risk in storing a given liquid fuel at given temperature

Fire point

• The fire point of a liquid fuel is the temperature at which vapour given off by fuel will ignite and continue to burn when an external flame is applied

• In most of liquid fuels, fire point is not as clearly demarcated as flash point

Ignition point

• The ignition temperature is the lowest temperature at which the liquid fuel will spontaneously combust in a normal atmosphere, such as a flame or spark.

• This temperature is required to supply the activation energy needed for combustion.

Flammability limit

• The minimum concentration of vapor of liquid fuel in air below which propagation of flame does not occur on contact with a source of ignition. This is known as lower flammability limit ( LFL).

• There is also upper flammability limit (UFL)

• Flammability is generally expressed as percentage of vapour volume in air

Flammability limit cont.

• If the vapour –air mixture temperature is higher, the LFL is reduced. increasing the temperature by 100 C decreases the LFL value about 8%.

• Lower flammability for HSD is approximately 9 %