1. Guwahati Refinery : Indian Oil Corporation Ltd
Presentation
on Risk
invloved in transportation of hazardous
chemical and flammable hydrocarbon
and
its management
A Bairagi
Production Manager
Guwahati Refinery : Indian Oil Corporation Ltd

2. Risk Concept Risk is defined as the uncertainity of occurence of
any unforseen event/activity in relation to the liklihood
that may occur
Risk comprises of two variables
Magnitude of consequences
Likelihood of occurrence 2

3. Likelihood Very Likely -- Could happen frequently
Likely -- Could happen occasionally
Unlikely -- Could happen, but only rarely
Highly Unlikely -- Could happen but probably never will 3

4. Likelihood When evaluating the likelihood of an accident,
a factor that will modify the likelihood category, is exposure.
Very Rare -- Once per year or less
Rare -- A few times per year
Unusual -- Once per month
Occasional -- Once per week
Frequent -- Daily
Continuous -- Constant 4

5. Individual Perceptions
-- Risk is a very individual concept.
-- It is different for every one. 5

6. Risk Therefore the perception of a HAZARD and its RISKS also changes.
Another thing to consider is that peoples’
perceptions change as familiarity increases.
Therefore the perception of a
HAZARD and its RISKS also
changes. 6

7. Risk Assessment Risk: The possibility of an unwanted event occurring
Likelihood:
The chance of an event actually occurring. 7

8. Risk Assessment and Criteria
Risk criteria are to be applied within the context
of a standard methodology.
Several countries have evolved criteria suitable to
their requirements for the use of risk analysis as an
aid to decision making 8

9. Risk Assessment and Criteria
Workable Risk criteria recognises that:
There is a level of risk that is so high that it is considered unacceptable or intolerable regardless of the benefits derived from an activity.
There is also a level of risk that is low enough as to be considered negligible.
Levels of risk in between are to be considered tolerable subject to their being reduced As Low As is Reasonably Practicable (ALARP). 9

10. Risk Assessment and Criteria
- The ALARP Principle
Risks are only tolerable provided that :
It can be demonstrated that all
Reasonably Practicable measures
have been implemented to reduce the risks.
A reasonably practicable risk reduction measure is one where the costs of implementation are not grossly disproportionate to the risk reduction benefits achieved. 10

11. Principle Of Economics
Cost of
losses
Optimal Point
Cost of
control 11

12. 12

13. Risk Assessment 13

14. Structured Safety Tours Group Risk Assessments
‘QUALITATIVE’
Walk Through Audits
Structured Safety Tours
Safety Audits
Group Risk Assessments
Job Safety Analysis
‘WHAT IF’ Analysis
Fault Tree analysis
HAZOP
QUANTATIVE’
Risk Analysis 14

15. Risk Analysis 15

16. Release Incidents Pump seal leaks Rupture of a transfer pipe or hose
Valve seal leaks
Flange gasket leaks
Corrosion failure of vessels/pipes
Vessel failure - BLEVE
Over filling
Water draining 16

17. Escalations Quantity of LPG release Weather condition Ignition sources
Operator response 17

18. Hazards Vapour cloud formation and explosion
Damage due to over pressure
Fires Thermal damage
BLEVE
- Overpressure
- Rocketing tank parts
- Fire ball 18

19. RISK ON HAZARDOUS CHEMICAL19

20. CHEMICALS
SOLIDS
LIQUIDS
GASES
VAPOURS

21. Acts/Rules
Industries handling hazardous chemicals are covered by the following Acts/Rules:
The Factories Act, 1948, as amended in 1987
The Manufacture, Storage and Import of Hazardous Chemicals (Amendment) Rules, 2000 : (MSIHC Rules)
The Public Liability Insurance Act, 1991as amended in 1992
The Central Motor Vehicles Rules, 1989
The Railway Red Tariff Rules, 1960 as amended
The Chemical Accidents (Emergency Planning, Preparedness and Response) Rules, 1996

22. Chemical Hazard Due To
Inhalation
Ingestion
Skin Contact
Accidental

23. Ammonia : NH3 Routes of Entry : Inhalation, Skin or Eyes
Effects of Exposure/ symptoms 700 ppm causes eye irritation and permanent injury may result if prompt medical remedial measures are not taken ppm may cause death. Contact of the liquid with skin freezes the tissues and causes the caustic burns. Respiratory track irritant. Irritation to cornea and tearing, liquid contact with eyes, partial or total blindness if not treated immediately. Chemical burns and frostbite.

24. Ammonia : NH3 Personal Protective Equipment
Avoid contact with liquid or vapours
Provide rubber boots, safety goggles, self-contained breathing apparatus, gas mask and protective clothing in case of liquid ammonia.

25. Carbon mono oxide : CO Routes of Entry : Inhalation, Skin and Eyes
Human systematic effects by inhalation, changes in psycho-physiological tests and preventing haemoglobin from binding oxygen. Contact of liquid CO with skin causes frostbite. Eye contact causes severe injury.

26. Carbon mono oxide : CO Personal Protective Equipment
Avoid contact with liquid or vapours.
Provide self-contained breathing apparatus, face shield or safety goggles, safety shoes, appropriate canister mask, rubber over-clothing, hand gloves.

27. Chlorine : Cl2 Routes of Entry: Inhalation, Ingestion, Skin and Eyes.
Effects of Exposure/ Symptoms : Causes Eye irritation, sneezing, copious salivation, general excitement, restlessness. High concentration causes respiratory distress and violent coughing, often with retching. Death may result from suffocation.

28. Chlorine : Cl2 Personal Protective Equipment
Avoid contact with liquid or vapour.
Provide PVC gloves, gumboots, rubber overcoat, head mask, self-contained breathing apparatus.

29. Hydrogen : H2 Routes of Entry : Skin, Inhalation
Effects of Exposure/ Symptoms: If atmosphere does not contain enough oxygen, inhalation causes dizziness, unconsciousness or even death. Contact with eyes or skin or liquid H2 causes freezing similar to burn.

30. Hydrogen : H2 Personal Protective Equipment
Avoid contact with liquid or gas
Provide safety goggles, face shied, insulated gloves and long sleeves, trousers Worn over high top shoes to shed spilled liquid, self-contained breathing apparatus containing air (never use oxygen).

31. Hydrochloric acid : HCl
Routes of Entry : Inhalation, Ingestion, skin and Eyes
Effects of Exposure/ Symptoms. Inhalation: The major effects of acute exposure to HCL are usually limited to upper Respiratory tract. Exposure to the gas causes cough, burning of the throat and larynx and Choking feeling, inflammation and ulceration of the nose, throat and larynx. Exposure to Higher concentration may cause laryngeal spasm, and oedema of the lungs and vocal Cords. Prolonged or repeated exposure may cause dental decolouration and erosion. Gastritis and chronic bronchitis have also been reported in exposed workers. Giddiness, Mental confusion and nausea.

32. Hydrochloric acid : HCl
Skin contact: Cause skin burns and may produce keloid and rectile scarring. Facial burns May result in serious and disfiguring scars. Frequent contact with dilute acid may cause Dermatitis and photo-sensitisation may result from industrial contact.
Eye Contact: Hydrochloric acid is a strong eye irritant and contact with the acid may Cause burns, reduced vision and total blindness.
Ingestion: Ingestion of HCL causes severe burns and corrosion of mouth oesophagus and Stomach. Symptom include dysphasia, pain, nausea, vomiting , Diarrhoea and thirst. Circulatory collapse may occur and ingestion may lead to fatal effects from oesophagus or gastric necrosis.

33. Hydrochloric acid : HCl
Personal Protective Equipment
Approved respirator, Safety goggles, neoprene, viton or butyl rubber glove and acid resistant outer clothing
Mechanical exhaust.

34. Hydrogen Sulphide : H2S Routes of Entry : Inhalation, skin & eyes
Effects of Exposure/ Symptoms, Inhalation : If high concentrations are inhaled, hypernoea & piratory paralysis may occur. Very high concentration may produce pulmonary edema.
Skin & eyes: Causes severe irritation.

35. Hydrogen Sulphide : H2S Personal Protective Equipment
Avoid contact with gas.
Provide rubber framed side covered goggles, approved respirator, rubber hand gloves, over-clothing and shoes.

36. Caustic Soda : NaOH
Routes of Entry :Inhalation, Skin, Ingestion & Eyes.
Effects of Exposure/ Symptoms - Inhalation : Causes small burns to upper respiratory tract & lungs, mild nose irritation.
Ingestion : Causes severe damage to mucous membrane, severe scaring or perforation may occur.
Eyes: Severe damage.
Skin: Causes severe burns.

37. Caustic Soda : NaOH Personal Protective Equipment
Avoid contact with solid or liquid.
Provide side covered safety goggles, face shield, filter or dust-type respirator, rubber shoes and rubber hand gloves.

38. Sulphur-di-oxide : SO2 Routes of Entry : Inhalation, Eyes and Skin
Effects of Exposure/ Symptoms Vapour causes irritation of eyes & lungs with severe choking. Liquid will cause frostbite. Vapours are poisonous, if inhaled.

39. Sulphur-di-oxide : SO2 Personal Protective Equipment
Avoid contact with liquid or vapours.
Provide air supplied mask or approved canister, safety goggles or face-shield, rubber hand gloves, shoes, aprons.

40. Sulphuric Acid : H2SO4 Routes of Entry: Inhalation, contact, ingestion
Effects of Exposure/ Symptoms : Irritates eyes, nose, throat, dental erosion, skin and eyes, burn. Causes deep burn to tissue. Very dilute solution causes dermatitis. Exposure cause bronchitis.

41. Sulphuric Acid : H2SO4 Personal Protective Equipment
Rubber gloves, safety goggles, acid proof overalls. Provide safety shower, eyewash Fountain, self contained breathing apparatus.

42. Hazard Control To reduce hazardous exposure methods include
Mechanical ventilation
Process or personnel enclosure
Control of process conditions & modification
Administrative control
PPE

43. Storage Limit quantity of material in storage
Appropriate warning signs.
Keep storage area separate from work areas.
Provision of leak detection and alarm systems
Store cylinders upright on a level, fire proof floor, secured in position to
Protect from damage
Keep valve cover on
c) Keep filled cylinders separately from empty cylinders.

44. Handling Move cylinders by hand truck or cart designed for that
Don’t lift cylinders by their caps
Don’t handle them with oily hands.
Don’t drop them or permit them to bang against each other.
Close all valves when, not in actual use.
Open & shut the valves at least once a day, while cylinder is in use, “to avoid valve freezing”.
Have emergency equipment readily available.

45. HAZCHEM CODIFICATION
HAZCHEM Code is based on pictorial representations consist of a diamond, as shown in the figure, divided into 4 parts. These parts, starting from left block (in clockwise direction), represent Health Hazard, Flammability Hazard, Reactivity Hazard and Space for additional information such as water reactivity, oxidant and radiation hazard. The colour codes for these hazards are : blue for health, red for flammability, yellow for reactivity and colourless for additional information. The intensity of hazard is grouped into five classes with numerical indications as 0, 1, 2, 3 & 4 in the ascending order of hazard intensity. In the following lines, these hazard intensities are explained, with the numeral on the left indicating the hazard intensity.

46. HAZCHEM CODE Flammability (Red) Reactivity Health (Yellow) (Blue) W
OXY
W : Indicates possible hazard in use of water.
OXY: Indicates oxidizing chemicals.

47. CLASSIFICATION OF HAZARDOUS SUBSTANCES
The hazardous substances are classified into eight classes. These are as under :
CLASS 1 EXPLOSIVES
  CLASS 2 GASES, COMPRESSED, LIQUEFIED, DISSOLVED OR DEEPLY REFRIGERATED, INFLAMMABLE GASES, POISON (TOXIC) GASES.
  CLASS 3 INFLAMMABLE LIQUIDS
  CLASS 4 INFLAMMABL SOLIDS, SUBSTANCES LIABLE TO SPONTANEOUS CONBUSTION; SUBSTANCES WHICH ON CONTACT WITH WATER EMIT INFLAMMABLE GASES.
  Division 4.1 Inflammable solids
  Division 4.2 Substances liable to spontaneous combustion.
  Division 4.3 Substances, which in contact with water, emit inflammable gases.
CLASS 5 OXIDISING SUBSTANCES
  Division 5.1 oxidizing substances
  Division 5.2 Organic peroxides
  CLASS 6 POISONOUS (TOXIC) AND INFECTIOUS SUBSTANCES
  Division 6.1 Poisonous (toxic) substances
  Division 6.2 Infectious substances
  CLASS 7 RADIOACTIVE SUBSTANCES
  CLASS 8 CORROSIVES
For details, the Central Motor Vehicles Rules may be referred.

48. MATERIAL SAFETY DATA SHEET
This section includes safety data sheets of most of the hazardous chemicals being used in Petroleum Industry. The data provided are compiled from various data sources as given in Reference. The identity of the chemical is defined in para 1 of the safety data sheet and important physical and chemical properties of each chemical have been given in para 2 of the safety data sheet. The fire & explosion data, reactivity data, health hazardous data have been given vide Para 3, 4 & 5 respectively. The preventive measures and emergency & first aid measures and additional information / references, if any, are given in Para 6,7 & 8 respectively. Individual data sheets are to be supplemented with the following as item 9 and 10.
9. MANUFACTURER’S / SUPPLIER’S DATA
  Name of Firm Contact Person in Emergency
  Mailing Address
Telephone/Telex Nos.: Local Bodies involved.
Telegraphic Address :
  Standard Packing
Details / Ref.
Other
  10. DISCLAIMER
  Information contained in this material data sheet is believed to be. It is up to the manufacturer / seller to ensure that the information contained in the material safety data sheet is relevant to the product manufactured or sold by him, as the case may be.

49. RISK ON HYDROCARBON INDUSTRY

50. DEFINITIONS
HAZARD
SITUATION WITH A POTENTIAL FOR DAMAGE TO MEN, MACHINES AND ENVIRONMENT.
EX : FIRE / EXPLOSION

51. MAJOR REFINERY POTENTIAL HAZARDS
FIRE HAZARD
EXPLOSION HAZARD
ELECTRICAL HAZARD
TOXIC GAS RELEASE HAZARD
HAZARDOUS CHEMICAL HAZARD
OIL SPILLAGE
RADIATION HAZARD
FALL FROM HEIGHT

52. Special Risks Associated with Petroleum Refining
Highly flammable material
High Temperature/Pressure
Harmful Chemicals/Solvents/Catalysts used in the Process
Corrosivity /Reactivity
Self Ignition on Leakage from System
Uncontrolled Process Reactions
Loss of Containment/Accidental Releases

53. WHAT IS FIRE ?
Fire is a phenomenon which evolve heat and light energy upon burning a carbonaceous material.
Chemically, it is an exothermic chemical reaction resulting from the combination heat, fuel and oxygen.
Fire involves rapid oxidation at high temperatures accompanied by the evolution of highly heated gaseous products of combustion and emission of visible and invisible radiation

54. 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).

55. FIRE TRIANGLE
HEAT
OXYGEN
FUEL

56. FIRE THREE ELEMENTS ARE NECESSARY FOR INITIATION OF FIRE:
FUEL IN THE FORM OF VAPOUR, LIQUID OR SOLID.
A SOURCE OF IGNITION SUFFICIENT TO INITIATE & PROPAGATE THE FIRE.
OXYGEN IN SUFFICIENT PROPORTION TO FORM A COMBUSTIBLE MIXTURE.

57. METHODS OF EXTINGUISHMENTS OF FIRE
STARVATION : ELIMINATION OF FUEL
SMOTHERING : LIMITING OF OXYGEN
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.

58. 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.

59. 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.

60. CLASSIFICATION OF PETROLEUM PRODUCTS
CLASS –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.

61. DEFINITIONS FLASH 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.

62. FLAMMABLE OR EXPLOSIVE LIMIT
In the case of gases or vapour, which form flammable mixtures with air, there is a minimum concentration of vapour in air below which the propagation of flame does not occur in contact with a source of ignition. This is called Lower Explosive Limit (LEL). Similarly, there is a maximum concentration of vapour above which the propagation of flame does not occur on contact with a source of ignition. This is called Upper Explosive Limit (UEL). This range of minimum to maximum concentration is termed as Flammable or Explosive range.
The flammable limits are not appreciably changed by normal variations in atmospheric pressure and temperature. However, at high temperatures, the upper limit is raised and the lower limit lowered, resulting in greater flammable or explosive range. The effect of high pressures on the limits is different for each gas or vapour depending upon its nature.

63. 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 2.
HYDROGEN
585
GAS
4.1
74.0 3
METHANE
538
5.0
15.0 4
ETHANE
514
3.0
12.5 5
PROPANE
466
2.4
9.5 6
BUTANE
430
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 12
SKO
254 35

64. 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 17 FO 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
GAS
1.8
9.6

65. LIQUEFIED PETROLEUM GAS (LPG)
PHYSICAL PROPERTIES:
IT IS A MIXTURE OF PROPANE & BUTANE.
COLOURLESS BOTH AS A LIQUID AND A VAPOUR.
LPG IS ODOURLESS, BUT USUALLY ADDED TRACE QUANTITIES OF
ODORING AGENT(MERCAPTAN) TO ENABLE DETECTION BY SMELL.
DENSITY: LIQUID LPG IS ONLY HALF THE WEIGHT OF WATER.
: LPG AS A GAS IS TWICE THE WEIGHT OF AIR.
  EXPLOSIVE LIMIT : % VOL.IN AIR.
IGNITION TEMPERATURE : Oc.
LIQUID TO GAS EXPANSION: 1:250
VAPOUR PRESSURE AT 37.5 Oc = 7.7 kg/cm2(Appox)

66. LIQUEFIED PETROLEUM GAS (LPG)
FIRE HAZARD:
EXTREMELY FLAMMABLE GAS
DANGEROUS WHEN EXPOSED TO HEAT OR FLAME. IT BURNS WITH A BLUE FLAME WHEN MIXED WITH CORRECT PROPORTION OF AIR. IF THE AIR SUPPLY IS INSUFFICIENT, THE FLAME BURNS YELLOW AT THE EDGES. NO SMOKE IS PRODUCE DURING BURNING.
HEALTH HAZARD:
LPG CONTAINS NO TOXIC COMPONENTS SUCH AS CARBON MONOXIDE AND IS THEREFORE NON POISONOUS.
INHALATION: EXPOSURE TO HIGH CONC. OF LPG WILL PRODUCE UNCONSCIOUSNESS & SUBSEQUENT ASPHYXIATION.
SKIN AND EYE CONTACT: IF LIQUID LPG COMES INTO CONTACT WITH UNPROTECTED SKIN AND EYES THEY WILL EVAPORATE QUICKLY AND THE COOLING EFFECT COULD PRODUCE FROST BITE OR COLD BURNS.
TLV(TWA): 1000 PPM

67. LIQUEFIED PETROLEUM GAS (LPG)
FACTORS AFFECT RATE OF EVAPORATION DURING LPG SPILL
 AMBIENT TEMPERATURE
WEATHER CONDITIONS
SLOPE OF THE GROUND
CONDUCTIVITY OF THE GROUND
SURFACE AREA OF THE SPILL(ANY OBSTRUCTIONS SUCH AS BOUNDARY WALLS WILL SLOW RATE OF EVAPORATION).
IF WATER IS SPRAYED ONTO A LPG LIQUID SPILL, IT WILL ACT AS A HEAT SOURCE AND INCREASE THE EVAPORATION RATE.

68. LIQUEFIED PETROLEUM GAS (LPG)
TYPES OF INCIDENTS ARISING FROM COMBUSTION
 A.   NORMAL FIRES
 OFTEN RESULT FROM IMMEDIATE IGNITION FOLLOWING A SPILL.
USUALLY BURNS WITH A DIFFUSED FLAME WITH NO EXPLOSION.
RADIATION CAN IGNITE OTHER COMBUSTIBLES IN THE AREA
 SOLUTION: CUT OFF AIR/FUEL SUPPLY TO FLAME & APPLY COOLING
B.   FLASH FIRES
 IGNITION OF OVERRICH CLOUD OF FUEL IN AIR
FLAME BURNS BACK AGAINST CLOUD
GENERALLY NO EXPLOSION
CAN IGNITE OTHER SOURCES OF FUEL

69. LIQUEFIED PETROLEUM GAS (LPG)
      BLEVE
A BOILING LIQUID EXPANDING VAPOUR EXPLOSION IS STARTED BY THE HEATING OF A VESSEL CONTAINING FLAMMABLE LIQUID BY AN EXTERNAL FIRE.
CONTENT IS HEATED ABOVE ITS BOILING POINT AND PRESSURE IN THE VESSEL INCREASES

70. LIQUEFIED PETROLEUM GAS (LPG)
IF FLAMES IMPINGE ON THE UN WETTED SURFACE OF THE TANK ON OR NEAR THE EMPTY SPACE, THIS AREA WILL BE WEAKENED AND MAY FAIL AS INTERNAL PRESSURE DEVELOPS.
THE VESSEL RUPTURES AND PIECES CAN BE PROPELLED CONSIDERABLE DISTANCES
THE SPILLAGE OF THE OVERHEATED LIQUIDS AND THEN IGNITION CREATES A LARGE FIREBALL WITH EXPLOSION PRESSURE EFFECTS.
SOLUTION:
KEEP TANK COOL
EXTINGUISH EXTERNAL FIRES

71. LIQUEFIED PETROLEUM GAS (LPG)
D. UVCE
AN UNCONFINED VAPOUR CLOUD EXPLOSION IS AN EVENT WHERE A FLAMMABLE FUEL/AIR CLOUD BURNS IN FREE SPACE, GENERATING SHOCK WAVES.
COMBUSTION MECHANISM STARTS FROM A POINT OF IGNITION SOURCE, WITH THE FLAME FRONT ACCELERATING FROM A LOW INITIAL VELOCITY TO SONIC VELOCITY.
MAGNITUDE OF BLEVE:
PIECES OF CONTAINER CAN SHOOT OFF SOME 1000 METRE OR MORE DISTANCE.
DEATH FROM SUCH MISSILES MAY OCCUR UPTO 250 M.
FIRE BALLS OF 30 METRE (HUNDRED FEET) DIAMETRE IS NOT UNCOMMON.
SEVERE BURN DAMAGE IN A M RADIUS.
A SHOCK WAVE FROM BLEVE CAN BREAK WINDOWS SEVERAL KILOMETER AWAY
FLAME TEMPERATURES AS HIGH AS 1200 deg C.
REMEMBER: THERE IS NO SAFETY PERIOD, A BLEVE CAN OCCURS AT ANY TIME.`

72. LIQUEFIED PETROLEUM GAS (LPG)
RELIEF VENT OPENS AT 17.6 kg/cm2
HOT AREA
UNEXPOSED SHELL
VAPOUR
LIQUID
SUPPORT
SLOP
TANK SHELL OVERHEATED ABOVE LIQUID LEVEL

73. LIQUEFIED PETROLEUM GAS (LPG)
FIRE FIGHTING PROCEDURES-BLEVE SITUATIONS
WHEN THERE IS NO RISK TO LIFE OR PROPERTY, SERIOUS CONSIDERATION MUST BE GIVEN TO EMPLOYING A “NON ATTACK STRATEGY.
IF A DECISION IS MADE TO ATTACK THE FIRE THEN IMMEDIATE, MASSIVE WATER-COOLING MUST BE APPLIED CONCENTRATING ON EXPOSED VAPOUR SPACE.
PERSONNEL SHOULD BE FULLY BRIEFED AND MADE AWARE OF THE DANGER CONFRONTING THEM.
CHANGE FROM HAND HELD BRANCHES TO GROUND MONITORS
USE OF WATER SPRAY ON EXPOSED CREW TO GIVE PROTECTION AGAINST FIRE EFFECTS.
EVACUATION OF THE SURROUNDING ARES MIN M.
REMEMBER THAT RELATIVELY HIGH RISK AREA IS AN “END ON” DIRECTION. HOWEVER, FRAGMENTS AND MAJOR TANK SECTION CAN FLY IN ANY DIRECTION.

74. VAPOUR CLOUD
WHEN LIGHT HYDROCARBONS LIKE NAPHTHA, MS OR FLAMMABLE GASES LEAK IT VAPOURISES AND FORMS AN EXPLOSIVE MIXTURE WITH AIR. WHEN THE LEAK IS HEAVY AN EXPLOSIVE CLOUD IS FORMED. THIS CLOUD IS KNOWN AS A VAPOUR CLOUD.
WHENEVER THIS VAPOUR CLOUD COMES IN CONTACT WITH A SOURCE OF IGNITION IT CAN EXPLODE AND CAUSES FROM THE VEHICLES, SMOKING OR OTHER SOURCES OF IGNITION.
FORMATION OF VAPOUR CLOUD
LEAKAGE FROM PIPELINES: IT MAY BE ON THE ROAD SIDE, INSIDE THE UNITS OR IN THE TANK FARM.
LEAKAGE FROM TANKS OR TANK OVERFLOW: IT MAY BE IN THE TANK FARMS OR FROM THE TANKS IN THE UNITS AREA.
LEAKAGE FROM TANKERS OR OVERFLOW OF TANKER: IT MAY BE IN WAGON LOADING GANTRY AREA.

75. VAPOUR CLOUD LEAKAGE OF LPG: IT MAY BE IN THE FOLLOWING AREAS;
INSIDE PROCESS UNITS OR ALONG ROAD SIDE LINE LEAKAGE .
LEAKAGE FROM ROAD TANKER, WAGONS, FILLING HOSES, HORTON SPHERES OR FROM CONNECTING PIPES.
LEAKAGE FROM CYLINDERS, FILLING MACHINES, PUMPS OR CONNECTING PIPES.
HOW TO IDENTIFY VAPOUR CLOUD:
BY SMELL: IF IT IS EXTRA ORDINARY ON HIGHER SIDE.
BY MIST : IN MOST OF THE CASES MIST FORMATION TAKES PLACES.
BY LEAK: IF HYDROCARBON LEAK IS VISIBLE.

76. VAPOUR CLOUD IMPORTANT DO’S AND DON’TS IN CASE OF VAPOUR CLOUD: DO’S
INFORM CONCERNED UNIT PERSONNEL AND FIRE STATION .
NEVER ALLOW ANY VEHICLE TO ENTER IN THE AREA. DO NOT OPERATE ANY ELECTRICAL SWITCHES.
CORDON-OFF THE AREA
NEVER ALLOW ANY VEHICLE TO START IN THE AFFECTED AREA.
GUIDE THE UNIT PERSONNEL/FIRE PERSONNEL
IF VEHICLE IS ALREADY IN THE AFFECTED AREA, REMOVE IT BY PUSHING.
IN CASE OF VAPOUR SMELL, TRY TO DETECT THE SOURCE OF LEAK
DURING PATROLLING IF STRONG SMELL OF HYDROCARBONS OR ANY LEAK DETECTED STOP THE ENGINE IMMEDIATELY AND MOVE ON FOOT TO DETECT THE LEAK.
STOP ALL HOT JOBS AND SMOKING BOOTHS
NEVER SMOKE OR ALLOW THE SMOKING INSIDE THE BATTERY AREA.

77. Effect of Blast Overpressure

78. Effects of Thermal Radiation

79. BLEVE Fireball Fireball radius : R = 29 M1/3 .
Where R= Fireball radius (in meters).
M=Mass of fuel (te).
Fireball duration :
t = 4.5 M1/3 .
Where t= duration (in sec).

80. BLEVE Fireball M is usually taken as half the tank capacity,
I.e. for a 50 te LPG tank, M=25te .
If , however , storage is in a close grouping of three or more vertical tanks, it is recommended that M is taken as 90 percent of tank capacity.

81. BLEVE Fireball
The radiative flux incident on a target some distance away from the LPG tank is given by : qt = EFT .
Where ,
qt = radiative flux incident on target (kWm-2 ).
E= surface emission power (kWm-2).
F= view factor.
T= atmospheric transmissivity.
E is taken as 270 kWm-2 for cylinder , horizontal and vertical tanks .
and 200 kWm for spheres .
F is taken as R2 r / (R2 + r2 )3/2

82. BLEVE Fireball
Where r is the ground level distance between target and LPG tank.
(r should be greater than 2R.)
T is determined by the relationship
T= In r.
Once qt has been determined , than a thermal dose or pulse can be calculated as qt X t.
Where t= duration of fireball.

83. BLEVE Fireball
For example , the incident thermal radiation flux of a BLEVE fireball at a distance of 300m from a 100te LPG tank.
R=29M1/3 = 29 X 501/3 = 107m.
t=4.5M1/3 = 4.5 X 501/3 = 16.6 sec.
E= 270 kWm-2.
T = In r = In 300 = 0.67.
F= R2r / (R2+rr)3/2 = 1072 X 300 / ( )3/2=0.016.
qt = EFT = 270 X X 0.67 = 19.2 kWm-2.
thermal dose or pulse = qt X t = 19.2 X 16.6 = 317 kJm-2

84. BLEVE Quantity, MT Fire Ball Size M Exclusion Zone 1 30 90 5 50 190 1063
230
110
420
100
140
500
Speed of Missiles :
Horton Sphere : m/sec
Bullet : m/sec
Distance traveled by fragments
Horton Sphere : M
Bullet : M 84

85. Vapour Cloud Explosion
Assumption-
LPG tank full when catastrophic failure causes quasi – instantaneous release.
Vapour / aerosol cloud is twice adiabatic flash fraction at 150 C , I.e. 62 percent and 34 percent of the tank contents for propane and butane respectively.
1te LPG = 0.42te TNT.
For example , detrmine the overpressure at a distance of 300m from a 100te propane tank:
Scaled distance = distance / (0.42M X 62)1/3
Where M = mass of fuel in cloud (te).
= 300 / (0.42 X 62)1/3 = 101 m te1/3 .

86. Vapour Cloud Explosion
Scaled distance versus overpressure can be determined by the graph in the following slide
For example , the Overpressure of a BLEVE fireball at a distance of 300m from a 100te LPG tank.
The Overpressure = 2.23 psig

87. Vapour Cloud Explosion

88. Maximum liquid release for commercial LPGs
Maximum LIQUID release for Commercial LPG be determined by the graph in the following slide

89. Maximum liquid release for commercial LPGs

90. Maximum gas release for commercial LPGs
Maximum GAS release for Commercial LPG can be determined by the graph in the following slide

91. Maximum gas release for commercial LPGs

92. Maximum two phase release for commercial LPGs
Maximum TWO PHASE release for Commercial LPG can be determined by the graph in the following slide

93. Maximum two phase release for commercial LPGs

94. Chlorine The consequence of release of toxic gases like chlorine are:
- Time depended and,
- Will vary with distance and prevailing weather conditions.
Concentration and duration can be estimated using computer model which combine a physical description of the gas cloud Behaviour with experimental data.

95. Chlorine
Box type computer model are frequent used to predict the dispersion behaviors of gases like chlorine which are denser than air .
A model known as DENZ can be used for instantaneous release ( e.g. failure of a storage vessel) and gives information as shown by the graph in the following slide

96. Instantaneous Release of Chlorine

97. Chlorine
For Continuous release (e.g. from leaking pipe) a model known as CRUNCH will give information as shown by the graph in the following slide.

98. Continuous Release of Chlorine

99. Chlorine

100. Chlorine

101. HYDROGEN H2 PHYSICAL / CHEMICAL PROPERTIES :
PHYSICAL APPEARANCE : COLOURLESS
ODOUR : ODOURLESS
VAPOUR DENSITY : 0.07 AT 25 DEG. C (AIR=1) LIGHTEST GAS
FLAMMABILITY : HIGHLY FLAMMABLE / EXPLOSIVE
FLAMMABILITY LIMIT : 4% TO 75% IN AIR
FLASH POINT : <-50 DEG.C
AUTO IGNITION TEMPERATURE : 500 DEG CENTIGRADE
INCOMPATIBILITY : OXYDISING MATERIALS E.G. CHLORINE, BROMINE ETC.
MINIMUM SPARK IGNITION
ENERGY AT 1 ATM IN AIR : 0.02 MJ.

102. HYDROGEN H2 TYPICAL POTENTIAL HAZARDS:
THE MAJOR HAZARDS ASSOCIATED WITH HYDROGEN ARE FIRE & EXPLOSIONS AND IN THE EVENT OF CONTACT WITH THE LIQUID OR COLD BOIL OFF VAPOUR, FROSTBITE AND BURNS
HYDROGEN GAS CAN BURN IN TWO MODES, AS A DEFLAGRATION OR AS A DETONATION. IN A DEFLAGRATION, THE ORDINARY MODE OF BURNING, THE FLAME TRAVELS THROUGH THE MIXTURE AT SUBSONIC SPEEDS. THIS HAPPENS, FOR INSTANCE, WHEN AN UNCONFINED CLOUD OF HYDROGEN – AIR MIXTURE IS IGNITED BY A SMALL IGNITION SOURCE. UNDER THESE CIRCUMSTANCES, THE SEVERAL HUNDRED FEET PER SECOND. THE RAPID EXPANSION OF HOT GASES PRODUCES A PRESSURE WAVE. WITNESSES HEAR A NOISE, OFTEN A VERY LOUD NOISE, THE PRESSURE WAVE FROM RAPID UNCONFINED BURNING IS NOT EXTREMELY SEVERE, ALTHOUGH IT MAY BE STRONG ENOUGH TO DAMAGE NEARBY STRUCTURES.

103. HYDROGEN H2 TYPICAL POTENTIAL HAZARDS:
IN A DETONATION, THE FLAME AND THE SHOCK WAVE TRAVEL THROUGH THE MIXTURE AT SUPERSONIC SPEEDS. THE PRESSURE RATIO ACROSS A DETONATION WAVE IS CONSIDERABLY GREATER THAN THAT IN A DEFLAGRATION . THE HAZARDS TO PERSONNEL STRUCTURES AND NEARBY FACILITIES ARE ALSO GREATER IN A DETONATION.

104. HYDROGEN H2 HAZARDOUS PROPERTIES OF GASEOUS HYDROGEN
UNDETECTABILITY: HYDROGEN GAS IS COLOURLESS, ODOURLESS AND NOT DETECTABLE BY HUMAN SENSES. HYDROGEN LEAKS ARE MORE FREQUENTLY HEARD THAN SEEN.
FLAMMABILITY : MIXTURES OF HYDROGEN WITH AIR, OXYGEN OR OTHER OXIDIZERS ARE HIGHLY FLAMMABLE OVER A WIDE RANGE OF COMPOSITIONS.
AUTOIGNITION : TEMPERATURES OF ABOUT 1050OF (565OC) ARE USUALLY REQUIRED FOR MIXTURES OF HYDROGEN WITH AIR OR OXYGEN TO AUTO IGNITE AT 14.7 PSIA. HOWEVER, AT PRESSURES FROM 3-8 PSIA, AUTOIGNITIONS HAVE OCCURRED NEAR 650OF(343OC).

105. HYDROGEN H2
IGNITION AT LOW ENERGY INPUT : HYDROGEN AIR MIXTURES CAN IGNITE WITH VERY LOW ENERGY INPUT, 1/10TH THAT REQUIRED TO IGNITE A GASOLINE - AIR MIXTURE FOR REFERENCE, AN INVISIBLE SPARK OR A STATIC SPARK FROM A PERSON CAN CAUSE IGNITION.
LACK OF FLAME COLOUR : HYDROGEN – OXYGEN AND HYDROGEN – PURE AIR FLAMES ARE COLOURLESS (ANY VISIBLE FLAME IS CAUSED BY IMPURITIES). COLOURLESS HYDROGEN FLAMES CAN CAUSE SEVER BURNS.

106. HYDROGEN H2 EMERGENCY PROCEDURE
MAKE SURE THAT SOURCE OF IGNITION IS AVOIDED. EVEN AFTER ENSURING THAT THERE IS NO SOURCE SUSPECT THE PRESENCE OF A SOURCE OF IGNITION.
AS SOON AS LEAKS ARE DETECTED, IMMEDIATELY STOP OPERATIONS, SHUT OFF THE SOURCE OF SUPPLY, AND RELIEVE THE LINE OR SYSTEM OF ANY PRESSURE.
DON’T ACTUATE ELECTRICAL OR OTHER DEVICE HAVING QUESTIONABLE NON SPARKING CHARACTERISTICS RESUME OPERATIONS ONLY AFTER THE REPAIRS ARE COMPLETED.

107. HYDROGEN H2 DO THE FOLLOWING IN CASE OF LEAKAGE OF HYDROGEN
TAKE ACTIONS TO ENSURE THE SAFETY OF PERSONNEL (I.E. DON’T ALLOW PERSONS TO ENTER THE AREA AS THERE CAN BE FIRE / AND EXPLOSION).
CALL FIRE SERVICE
EVACUATE THE AREA
COOL DOWN ADJACENT EQUIPMENT TO PROTECT IT FROM POSSIBLE FIRE.

108. HYDROGEN H2 FIRE FIGHTING TECHNIQUES:
FLAME TEMPERATURE OF THE ORDER OF 3800OF (2093OC) CAN BE EXPECTED IN HYDROGEN GAS FIRES. CATASTROPHIC RESULTS FROM FIRES CAN BE PREVENTED BY TRAINING PERSONNEL TO :
PREVENT THE FIRE FROM SPREADING AND LET IT BURN UNTIL THE HYDROGEN IS CONSUMED (USE OF WATER TO KEEP ADJACENT EQUIPMENT COOL, DON’T ARREST THE FIRE.
BE AWARE THAT IF THE FIRE IS EXTINGUISHED WITHOUT STOPPING THE HYDROGEN FLOW, AN EXPLOSIVE MIXTURE MAY FORM, CAUSING A MORE SERIOUS HAZARD THAN THE FIRST ITSELF.
THE INVISIBLE FLAME CAN BE MANY FEET LONG AND CAN SHIFT QUICKLY WITH THE SLIGHTEST BREEZE. THEREFORE, PERSONNEL SHOULD WEAR PROTECTIVE CLOTHING WHILE FIGHTING HYDROGEN GAS FIRES.

109. FIRE RISK MANAGEMENT FIRE PREVENTION FIRE PROTECTION FIRE FIGHTING
FIRE RISK IS ‘THE CHANCE/POSSIBILITY OF LOSS DUE TO FIRE’.
THREE ASPECTS TO DEAL WITH FIRE RISK MANAGEMENT ARE:
FIRE PREVENTION
FIRE PROTECTION
FIRE FIGHTING

110. FIRE PREVENTION OBJECTIVE : TO ELIMINATE THE OCCURRENCE OF FIRE
REGULATIONS FOR THE PREVENTION OF FIRE
FIRE & EXPLOSION CONTRIBUTE A SERIOUS HAZARD TO HYDROCARBON PROCESSING INDUSTRY LIKE A PETROLEUM REFINERY. THE FOLLOWING REGULATIONS SHOULD BE STRICTLY FOLLOWED FOR PREVENTION OF FIRE.
REGULATION – 1:
FIRE OR NAKED LIGHT, MATCHES, PETROL OR OTHER LIGHTERS, CELLULAR PHONE OR ANY APPARATUS WHICH IS CAPABLE OF CAUSING IGNITION IS NOT PERMITTED TO BE TAKEN WITHIN THE BATTERY AREA BY ANY PERSON.

111. FIRE PREVENTION REGULATION – 2
NO FIRES SHALL BE LIT AND NO MATCHES IGNITED IN ANY PART OF THE BATTERY AREA UNLESS A VALID HOT WORK PERMIT HAS BEEN OBTAINED FROM THE AUTHORISED FIRE PERMIT SIGNATORIES OF THE AREA AND REGISTERED AT THE FIRE STATION
REGULATION-3
SMOKING IS PROHIBITED IN ALL PARTS OF THE BATTERY AREA EXCEPT IN THE SMOKING BOOTHS/LOCATIONS DULY APPROVED FOR THIS PURPOSE.
REGULATION – 4
CYCLE LAMPS, OTHER THAN DYNAMO OPERATED , ARE NOT ALLOWED IN THE REFINERY BATTERY LIMITS. THE CYCLIST WILL SWITCH OFF EVEN THE DYNAMO AS SOON AS HE ENTERS THE PLANT AREA.

112. FIRE PREVENTION
ORDINARY TORCHES WILL NOT BE USED WITHIN THE BATTERY AREA. FLAME PROOF TORCHES/LAMPS OF APPROVED MANUFACTURERS AS SUPPLIED BY THE REFINERY, SHALL ONLY BE USED.
REGULATION-5
ALL VEHICLES ENTERING / TRANSPORTING PETROLEUM PRODUCTS FROM THE REFINERY MUST BE FITTED ONLY WITH APPROVED TYPE OF SPARK ARRESTORS .
REGULATION-6
PERSONS ENTERING THE REFINERY BATTERY LIMIT SHALL DEPOSIT MATCH BOXES, LIGHTERS, MOBILES ETC WITH THE SECURITY AT THE MAIN ENTRANCE GATE OF THE REFINERY.

113. FIRE PROTECTION OBJECTIVE : TO CONTAIN THE SPREAD OF FIRE
FIRE PROTECTION PHILOSOPHY:
FIRE PROTECTION PHILOSOPHY IS BASED ON LOSS PREVENTION & CONTROL. BECAUSE OF THE INHERENT HAZARD A REFINERY CARRIES. NO PLANT IS ABSOLUTELY SAFE. A FIRE IN ONE PART/SECTION OF A PLANT CAN ENDANGER OTHER SECTIONS OF PLANT AS WELL
TYPES:
ACTIVE FIRE PROTECTION SYSTEM
PASSIVE FIRE PROTECTION SYSTEM

114. 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

115. 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

116. 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

117. FIRE FIGHTING
PORTABLE FIRE FIGHTING EQUIPMENT SHALL BE PROVIDED IN REFINERY/PROCESS PLANT AS INDICATED BELOW:
DESCRIPTION
NORMS/CRITERIA TO DETERMINE THE QUANTITY NEEDED
DRY CHEMICAL POWDER FIRE EXTINGUISHERS KG CAPACITY
TO BE LOCATED IN PROCESS UNITS, OFF-SITE AREAS , PLANT BUILDINGS , POWER DISTRIBUTION AREAS ETC.
THE NUMBER SHOULD BE DETERMINED BASED ON THE MAX. TRAVELING DISTANCE OF 15 mtrs IN ABOVE AREAS.
AT LEAST ONE FIRE EXTINGUISHER SHOULD BE PROVIDED FOR EVERY 250 sq. mt. OF HAZARDOUS OPERATING AREA.
DRY CHEMICAL POWDER FIRE EXTINGUISHERS 25/50/75 kg CAPACITY
TO BE LOCATED IN CRITICAL OPERATING AREAS. AT LEAST ONE FIRE EXTINGUISHER SHOULD BE PROVIDED FOR EVERY 750 sq. mt. OF HAZARDOUS OPERATING AREA.

118. FIRE FIGHTING DESCRIPTION
NORMS/CRITERIA TO DETERMINE THE QUANTITY NEEDED
CO2 EXTINGUISHERS OF 4.5 Kg OF 6.8/9.0 kg ON WHEELS
TO BE LOCATED IN SUBSTATIONS AND POWER STATIONS. THE NUMBER SHOULD BE DETERMINED BASED ON THE MAX. TRAVELING DISTANCE OF 15 mtrs.. AT LEAST ONE FIRE EXTINGUISHER SHOULD BE PROVIDED FORE EVERY 250sq. Mt. OF HAZARDOUS OPERATING AREA.
STEAM LANCERS (AS A PART OF UTILITY STATION)
FOR FIGHTING INCIPIENT FIRES AT FLANGE LEAKAGE & HOT PUMPS.
RUBBER HOSE REEL
TO BE LOCATED IN PROCESS (25 mm) UNIT BATTERY LIMITS AND OTHER PROCESS AREA.

119. FIRE FIGHTING S. NO. TYPE OF FIRE RISK EXAMPLE OF OCCUPANCIES
SCALE OF EQUIPMENT
1 A)
CLASS ‘A’ LIGHT HAZARD
OFFICERS (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

120. 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.

121. FIRE FIGHTING MOBILE FIRE FIGHTING EQUIPMENT FOAM TENDERS DCP TENDERS
FOAM NURSER
TRAILER FIRE PUMP
TROLLEY MOUNTED MONITORS
FIRE FIGHTING HOSE & OTHER ACCESSORIES LIKE FOAM BRANCH, NOZZLES ETC.
FIRE FIGHTING CHEMICALS LIKE FOAM COMPOUND, DRY CHEMICAL POWDER ETC.

122. GENERAL LOSS CONTROL RULES
NO MATCH BOX/ LIGHTER / MOBILE IS ALLOWED IN REFINERY
N0 SMOKING IS ALLOWED IN REFINERY EXCEPT AT DESIGNATED PLACES
  NO VEHICLE IS ALLOWED INSIDE BATTERY AREA WITHOUT SPARK ARRESTOR
  NOBODY IS ALLOWED TO ENTER THE REFINERY WITHOUT SHOES.
NO OUTSIDER IS ALLOWED INSIDE ANY OPERATIONAL PLANT / UNIT AREA WITHOUT PERMISSION OF AREA IN CHARGE.
  NO DEBRIS/OBSTACLES ALLOWED ON ROADS
NO PHOTOGRAPHY/VIDEOGRAPHY IS ALLOWED WITHOUT PERMISSION
  NO MAINTENANCE WORK SHOULD BE STARTED WITHOUT VALID PERMIT &
CLEARANCE.

123. GENERAL LOSS CONTROL RULES
NEVER ENTER WORK AREA WITHOUT HELMET WITH CHIN STRAP IN PLACE
· NO CLIMBING/WORKING ALLOWED WITHOUT SAFETY BELT ABOVE 2 METRE
HEIGHT
·  DO NOT WALK ON PIPELINES OR FALSE CEILINGS
 ·  DO NOT STAND UNDER SUSPENDED LOADS
 ·  DO NOT TAMPER WITH FIRE FIGHTING EQUIPMENT OR FIRE HYDRANTS
  ·  DO NOT EXCEED SPEED LIMIT OF 25 KMPH WITHIN THE REFINERY PREMISES.
  · REPORT ALL ACCIDENTS/INCIDENTS TO AREA INCHARGE AND FIRE &
SAFETY.
  ·   IN CASE OF TOXIC GAS RELEASE/DISASTER, ASSEMBLE AT DESIGNATED LOCATIONS.
  MAKE SAFETY A HABIT

124. WATER
The water is the best extinguishing media for Class A Fires. It is -
Readily available.
Have good absorbing capacity.
can be used as cooling agent, fire fighting, producing foam etc.
Water extinguishes the fire by cooling , smothering , emulsification [only in case of heavy oils], dilution.
Limitations: On
Energized equipments and
Water reactive metals.

125. FOAM
It is considered to be the best extinguishing medium for Class B fires.
The foam is the mass of air bubbles formed by aeration of foam solution made up of the water and foam concentrate.
The foam extinguishes the fire of liquid hydrocarbons Insulating the surface of fuel.Prevent release of vapours. Prevent mixing of vapour and atmospheric oxygen forming a blanket.
The foam is classified in two types depending on the method of generation
i.e. chemical and mechanical foam

126. Chemical foam
As the name suggests it is formed by the chemical reaction between the two chemicals namely Sodium bicarbonate and Aluminums Sulphide. The use is restricted to the portable extinguishers and now they are considered as obsolete.
6 NaHCO3 + Al(SO4)3 = 3Na2SO4 + 2Al(OH) + 6CO2

127. Mechanical foam
This foam is formed by mechanical agitation of the foam solution. There are various types such as protein foam, aqueous film forming foam, film forming fluoroprotein, alcohol resistant foam etc. used for fire fighting. 
Method of application of foam -- Foam should not be directly applied on the surface of the burning liquid whereas it should be applied in such manner so that it will slide down and spread on the surface of the burning liquid.

128. Aqueous film forming foam
Aqueous film forming foam (AFFF) UL Listed - It is the most commonly used synthetic foam in petroleum industries. It has unique property of forming a film on the surface of the liquid. It has low viscosity and surface tension. Hence it floats on the surface of the liquid and spreads to cover all the area. Even if the film is broken it has a characteristic to bleed back which means it reseals the surface due to which flashback is avoided. It has longer shelf life of minimum 15 years and excellent flashback resistance. Effective knocking down property on spill fires.

129. DRY CHEMICAL POWDER
The dry chemical powder is used to extinguish the Class B and Class C fires. The DCP for Class A fires is also available and for Class D fires special dry chemical is used.
The most commonly used DCP are:
1.   Sodium Bicarbonate.
2.   Potassium Bicarbonate.
3.   Monoammonium Phosphate. It also called as ABC powder as it can be used on Class A, B, C fires.
4. Monnex.: Urea based powder have decrepitating property to shatter into small particles of sub- micron size on approaching flame front. It is 6 times effective than ordinary DCP.
5. Ternary Eutectic Chloride : TEC powder is used to extinguish the combustible metal fires. The powder melts and forms the crust over the metal surface thereby extinguishing the fires. It is composed of three chlorides namely Sodium , Potassium and Barium Chloride.

130. EXTINGUISHMENT MECHANISM OF DCP
Sodium Bicarbonate: When DCP enters the combustion zone, it decomposes by the heat of the flame to liberate water, water vapours and carbon dioxide.
2 NaHCO Na2CO3 + H2O + CO2
The sodium Carbonate further decomposes to give
Na2CO Na2O CO
Na2O NaOH
Sodium Hydroxide produced during last step reacts with H & OH radicals which are active in fire to give water vapours.
  NaOH + H Na + H2O
NaOH + OH NaO + H2O
Also
NaO + H NaOH
Na + OH NaOH
This way all the H and OH radicals in fire are removed by breaking the chain reaction and thus extinguish the fire.

131. CLASS OF FIRE
DESCRIPTION
EXTINGUISHING MEDIUM
INDIAN STANDARD A
Fire involving ordinary combustible materials like wood, paper, textiles, etc. Where the cooling effect of water is essential for the extinction of fires
Water B
Fire inflammable liquids like oils, solvents, petroleum products, varnishes, paints etc. where a blanketing effect is essential
Foam ** carbon dioxide dry chemical powder. Not suitable for alcohol and other water miscible flammable liquids
(4308)-1982 C
Fires involving gaseous substances under pressure where it is necessary to dilute the burning gas at a very fast rate with an inert gas or powder.
Carbon dioxide dry chemical powder. The best way to extinguish such fires is by stopping the flow of fuel gas to the fire. Container is kept cool with water spray D
Fires involving metals like magnesium, aluminum, zinc, potassium etc. where the burning metal is reactive to water and which require special extinguisher media or technique
Special dry powder
(4861) – 1968
*As per IS:

132. 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 A REFINERY.
SOURCES OF IGNITION
EXAMPLE
PREVENTIVE MEASURES
ELECTRICAL EQUIPMENT
SPARKS FROM MOTORS, SWITCHES, LAMPS, HOT ELEMENTS AND ELECTRICAL DEFECTS
USE OF APPROVED EQUIPMENT
FOLLOW NATION ELECTRICAL CODES
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.

133. SOURCE OF IGNITION SOURCES OF IGNITION EXAMPLE PREVENTIVE MEASURES
SMOKING AS IGNITION
SMOKING BOOTHS IN AREA WHERE COMBUSTIBLE ARE USED
SMOKING ONLY IN AREAS PERMITTED.
USE OF PRESCRIBED RECEPTACLES FOR CIGARETTE BUTTS
SPONTANEOUS IGNITION
PYROPHORIC IRON, HOT OIL LEAKAGE
KEEP PYROPHORIC IRON WET ARE THE TIME WHEN IT IS TAKEN OUT.
HOT SURFACES
CONTACT OF COMBUSTIBLE MATERIAL WITHOUT SURFACES, HEATED LINES
PROVIDE PROPER INSULATION AND AIR CIRCULATION.
SPARK FROM ENGHINE EXHAUST
POL TRUCKS / DG SET
SPARK ARRESTOR ON EXHAUST

134. SOURCE OF IGNITION SOURCES OF IGNITION EXAMPLE PREVENTIVE MEASURES
STATIC ELECTRICITY
DURING SPLASH LOADING AND LOADING AT HIGH VELOCITIES
PROPER EARTHING OF EQUIPMENT.
DO NOT RESORT TO SPLASH LOADING
LOADING VELOCITY SHOULD BE CONTROLLED
LIGHTENING
THUNDERSTORM CLOUD BURST
PROPER LIGHTENING ARRESTOR AND EARTH CONTINUITY.

135. AREA CLASSIFICATION
Area classification is an assessment of dangerous atmosphere where there is possibility of release of a flammable substance in relation to a possible source of ignition from electrical instruments, equipments or static electricity. The aim is to reduce the probability of these risks to the minimum.
Hazardous area are divided into three zone 
Zone 0 Area: An area in which a flammable atmosphere is present continuously, or is present for long periods.
Zone 1 Area: An area in which a flammable atmosphere is likely to be present periodically or occasionally during normal operation.
Zone 2 Area: An area in which a flammable atmosphere is likely to occur in normal operation and if it does occur it will exist for a short time only.

136. FIRE HYDRANT NETWORK DISTRIBUTION NETWORK:
Network shall be laid in closed loops as far as possible to ensure multi-directional flow in the system. Isolation valves shall be provided in the network to enable isolation of any section of the network without affecting the flow in the rest. The isolation valves shall be normally located near the loop junctions. Additional valves shall be provided in the segments where the length of the segment exceeds 300 mts.
FIRE HYDRANTS:
Fire hydrants shall be provided in the network to ensure protection to all the facilities. The location of the hydrants shall be carefully decided keeping in view the easy accessibility. The maximum distance between two hydrants, however, shall not exceed 30 mtrs around hydrocarbon storage and hazardous areas and 45 mtrs in other areas. Each hydrant shall have two outlets inclined towards the ground. The outlets shall be of female instantaneous type having a standard size of 63.5 mm conforming to BIS.
HEADER PRESSURE:
The fire water system shall be designed for a minimum residual pressure of 7.0 kg/cm2 g at the hydraulically remotest point of application at the designed flow rate at that point.
The fire water network shall be kept pressurised at minimum 7.0 kg/cm2 gat all the time. In existing refineries, this shall be achieved in a phased manner.

137. FIRE WATER STORAGE
Water for the hydrant service shall be stored in any easily accessible surface or underground lined reservoir or above ground tanks. The effective capacity of the reservoir above the level of suction point shall be minimum 4 hours aggregate working capacity of pumps. Where make up water supply system is 50% or more this storage capacity may be reduced to 3 hours aggregate working capacity of pumps. Storage reservoir shall be in two equal interconnected compartments to facilitate cleaning and repairs.
Large natural reservoirs having water capacity exceeding 10 times the aggregate water requirement of fire pumps may be left unlined.
In addition to fire water storage envisaged as above, emergency water supply in the event of depletion of water storage shall be considered. Such water supplies may be connected from cooling water supply header and / or treated effluent discharge headers.
Fire water supply shall be preferably from fresh water source such as river, tube well or lake. Where fresh water source is not easily available, fire water supply may be sea water or other acceptable source like treated effluent water.

138. SELECTION OF FIRE FIGHTING PUMPS
Fire water pumps shall be used exclusively for fire fighting purposes.
TYPE OF FIRE PUMPS:
Electric motor driven centrifugal pumps.
Diesel engine driven centrifugal pumps.
The pumps shall be horizontal centrifugal type or vertical turbine submersible pumps. The pumps shall be capable of discharging 150% of its rated capacity at a minimum of 65% of the rated head. The shut-off head shall not exceed 120% of rated head, for horizontal pumps and 140% in case of vertical turbine type pumps.
CAPACITY OF PUMPS:
The capacity and number of main fire water pumps shall be fixed based on design fire water rate, to be worked out on the basis of design criteria
STANDBY PUMPS:
When total number of Working pumps work out to be one or two, 100% standby pumps shall be provided.
When total number of working pumps are more than two, 50% standby pumps shall be provided.
No. of diesel driven pumps shall be minimum 50% of the total no. of pumps and diesel pump capacity shall also be minimum 50%. Power supply to the pump motors should be from two separate feeders.

139. TYPICAL FIRE FIGHTING STRATEGIES
TANK FIRE:
Before attempting to extinguish fire in the tank, fire in the surrounding area i.e. in the dyke should be extinguished to reduce heat input to tank contents. Cooling the adjacent tanks (contents of which have not ignited but are exposed to radiation heat) by means of water spray/jet applied to shell to prevent excessive vaporization and to reduce the danger of fire spreading to other areas. Application of foam on seal of adjacent tank is also required.
When this heat wave reaches to the tank bottom, where some settled water is generally present, it will cause a violent “Boil-Over.” Burning oil first erupts and then falls, spreading even beyond the dyke of the tank. The columns of the flame can be very widely spread at the base. The beginning of a boil over is indicated by both increase in height and in brightness of the flames prior to actual eruption of the boiling oil. Immediate action will have to be taken to evacuate all personnel from the affected area and nearby areas. A “boil over” is a violent eruption. A boil over results from expansion or frothing of the heated liquid but is not as severe as a boil-over.

140. TYPICAL FIRE FIGHTING STRATEGIES
Heat-Wave:
In Case of wide boiling range ingredients in crude oil or product tank on fire, the lower boiling point hydrocarbons come out of the surface and feed the fire, while the higher boiling point hydrocarbons sink towards bottom forming a heated front to heat cold oil deeper and deeper as fire continues to burn. This phenomenon is called “heat wave.”
In case fire is not put out by the time heat wave has reached the point, 5 feet above known bottom water level (which can be roughly judged by peeling off/blistering of the external painting of the tank shell), it is to be ensured that all personnel are evacuated from the area. Be on guard from successive boil-overs form a burning tank since this will often occur.
Conduct all necessary work within the dyke area during the initial stages of the fire so that as the fire progresses, fire fighting operation can be carried out from a safer distance. Care must be taken NOT to get water in a heavy oil tank while fighting a fire thus reducing the possibility of boil-over.

141. SAFETY ASPECTS

142. NEED FOR SAFETY ECONOMIC ASPECTS LEGAL ASPECTS (STATUTORY OBLIGATION)
LOSS OF PRODUCTION
LOSS OF CAPITAL
LOSS OF MANPOWER
MEDICAL COMPENSATION
COST OF TRAINING
LOSS OF WAGES
BUSINESS INTERRUPTIONS
LEGAL ASPECTS
(STATUTORY OBLIGATION)
HUMAN ASPECTS
PHYSICAL INJURY
REPARATION ON FAMILY
MORAL LOSS
SOCIAL ASPECTS
GENETIC
ECOLOGICAL
LOSS TO NATION
POLLUTION OF STREAM AND AIR

143. SAFETY, HEALTH & ENVIRONMENT (S,H&E) POLICY
INDIAN OIL CORPORATION IS COMMITTED TO CONDUCT BUSINESS WITH STRONG ENVIRONMENT CONSCIENCE ENSURING SUSTAINABLE DEVELOPMENT, SAFE WORKPLACES AND ENRICHMENT OF QUALITY OF LIFE OF EMPLOYEES, CUSTOMERS AND THE COMMUNITY. WE AT INDIANOIL, BELIEVE THAT GOOD S,H&E PERFORMANCE IS INTEGRAL PART OF EFFICIENT AND PROFITABLE BUSINESS MANAGEMENT.
WE SHALL :
ESTABLISH AND MAINTAIN GOOD STANDARDS FOR SAFETY OF THE PEOPLE, THE PROCESSES AND THE ASSETS.
COMPLY WITH ALL RULES AND REGULATIONS ON SAFETY, OCCUPATIONAL HEALTH AND ENVIRONMENT PROTECTION.
PLAN, DESIGN, OPERATE AND MAINTAIN ALL FACILITIES, PROCESSES AND PROCEDURES TO SECURE SUSTAINED SAFETY, HEALTH AND ENVIRONMENTAL PROTECTION.

144. SAFETY, HEALTH & ENVIRONMENT (S,H&E) POLICY
REMAIN TRAINED, EQUIPPED AND READY FOR EFFECTIVE AND PROMPT RESPONSE TO ACCIDENTS AND EMERGENCIES.
WELCOME AUDIT OF OUR S,H&E CONDUCT BY EXTERNAL BODY, SO THAT STAKEHOLDER CONFIDENCE IS SAFEGUARDED.
ADOPT AND PROMOTE INDUSTRY BEST PRACTICES TO AVERT ACCIDENTS AND IMPROVE OUR S,H&E PERFORMANCE.
REMAIN COMMITTED TO BE A LEADER IN SAFETY, OCCUPATIONAL HEALTH AND ENVIRONMENT PROTECTION THROUGH CONTINUING IMPROVEMENT.
MAKE EFFORTS TO PRESERVE ECOLOGICAL BALANCE AND HERITAGE.

145. GENERAL LOSS CONTROL RULES
  NO MATCH BOX/ LIGHTER / MOBILE IS ALLOWED IN REFINERY
N0 SMOKING IS ALLOWED IN REFINERY EXCEPT AT DESIGNATED PLACES
  NO VEHICLE IS ALLOWED INSIDE BATTERY AREA WITHOUT SPARK ARRESTOR
  NO BODY IS ALLOWED TO ENTER THE REFINERY WITHOUT SHOES.
NO OUTSIDER IS ALLOWED INSIDE ANY OPERATIONAL PLANT / UNIT AREA WITHOUT PERMISSION OF AREA IN CHARGE.
  NO DEBRIS/OBSTACLES ALLOWED ON ROADS
NO PHOTOGRAPHY/VIDEOGRAPHY IS ALLOWED WITHOUT PERMISSION
  NO MAINTENANCE WORK SHOULD BE STARTED WITHOUT VALID PERMIT &
CLEARANCE.

146. GENERAL LOSS CONTROL RULES
· NEVER ENTER WORK AREA WITHOUT HELMET WITH CHIN STRAP IN PLACE
· NO CLIMBING/WORKING ALLOWED WITHOUT SAFETY BELT ABOVE 2 METRE
HEIGHT
·  DO NOT WALK ON PIPELINES OR FALSE CEILINGS
 ·  DO NOT STAND UNDER SUSPENDED LOADS
 ·  DO NOT TAMPER WITH FIRE FIGHTING EQUIPMENT OR FIRE HYDRANTS
  ·  DO NOT EXCEED SPEED LIMIT OF 25 KMPH WITHIN THE REFINERY PREMISES.
  · REPORT ALL ACCIDENTS/INCIDENTS TO AREA INCHARGE AND FIRE &
SAFETY.
  ·   IN CASE OF TOXIC GAS RELEASE/DISASTER, ASSEMBLE AT DESIGNATED LOCATIONS.
  MAKE SAFETY A HABIT

147. WORK PERMIT SYSTEM

148. WORK PERMIT SYSTEM
For performing any work in the refinery by any person other than the operating personnel of that area, a duly authorised written permit shall be obtained by the person/agency executing the work before commencement of the work.
Separate permit shall be obtained for each activity. Following jobs should be undertaken only after obtaining work permit:
Hot job, Excavation, Road/dyke cutting, Electrical lock-out/energising, Confined space entry, Boxing up of vessel/furnace/ column, Working at elevation, working on fragile roof structures, Radiography, Crane Operation.

149. WORK PERMIT SYSTEM Types of Work Permit
  Depending on the nature of the job, types of permit are:
1.     Cold Work
2.     Hot Work/Vehicle Entry
3. Radiography
4. Working at Height
5.     Confined Space Entry
6.    Excavation/Dyke Cutting /Road Cutting
7.   Electrical Work Permit.

150. WORK PERMIT SYSTEM General Requirements
· All jobs in the refinery shall be carried out under valid work permit only. Operating personnel do not require work permit.
·  Work permits in the refinery shall meet the requirements of OISD-STD-105 titled ‘Work Permit System’.
·  Permits should be in printed forms, in triplicate, serially numbered and different colour code may be adopted for different types of permits.
·  Depending on nature of jobs, type of permit required shall be decided .
·  ‘Working at Height Permit’ shall be required for working at a height of more than two meters from where the working personnel are liable to fall.

151. WORK PERMIT SYSTEM
Permit issuing authority shall satisfy him that permit conditions are met before issuing permit. It is also to be ensured that permit conditions are maintained in course of execution of the job.
Before issuing a permit, equipment is inspected to ensure that the area is cleaned and all safety precautions have been adopted. Wherever necessary, equipment is isolated, drained/ depressurised, properly purged, water flushed, gas test and oxygen deficiency test are done. Please refer OISD-105 for explanatory notes to work permits forms (reproduced from OISD-STD-105).
·  All concerned are to be trained on Work Permit System for proper implementation. Certification and documentation of the training imparted is a must.

152. ACCIDENT PREVENTION THROUGH PPE

153. ACCIDENT PREVENTION THROUGH PPE
ACCIDENTS CAN BE AVOIDED IN THE FOLLOWING TWO WAYS:
BY ELIMINATING OR REDUCING THE HAZARDS.
BY PROVIDING PROPER PROTECTIVE EQUIPMENT AND ENSURING THEIR USE BY CONCERNED PERSONNEL.

154. ACCIDENT PREVENTION THROUGH PPE.
OUR ENDEAVOR SHOULD BE TO ELIMINATE HAZARDS COMPLETELY BUT IT MAY NOT BE POSSIBLE IN ALL CASES.
THE NECESSITY ARISES FOR PROVIDING PERSONAL PROTECTIVE EQUIPMENT AS A SECOND LINE DEFENSE.
IT IS VERY NECESSARY THAT THE SELECTION OF THE PROTECTIVE EQUIPMENT IS PROPER. MOST OF THE INJURIES CAN BE ELIMINATED OR MINIMISED BY UTILIZING PROPER EQUIPMENT REQUIRED FOR THE JOBS:

155. ACCIDENT PREVENTION THROUGH PPE
FOUR ASPECTS TO BE TAKEN IN TO CONSIDERATION FOR ACCIDENT PREVENTION THROUGH PPE
NEED FOR PPE
SELECTION OF PPE
PROVIDING THE PPE
TRAINING AND USAGE

156. ACCIDENT PREVENTION THROUGH PPE
PROTECTIVE EQUIPMENT CAN BE DIVIDED INTO TWO CATEGORIES:
RESPIRATORY PROTECTIVE DEVICES.
NON-RESPIRATORY PROTECTIVE DEVICES

157. SUGGESTED OUTLINE FOR SELECTING RESPIRATORY PROTECTIVE DEVICES
RESPIRATORY HAZARD
OXYGEN DEFICIENCY
TOXIC GAS
TOXIC GAS & PARTICULATE
TOXIC PARTICULATE
IMMEDIATELY DANGEROUS
NOT IMMEDIATELY DANGEROUS
IMMEDIATE DANGEROUS
NOT IMMEDIATELY DANGEROUS

158. ACCIDENT PREVENTION THROUGH PPE
OXYGEN CONTENT IN AIR
SIGN AND SYMPTOMS OF PERSON AT REST
12% TO 14%
RESPIRATION DEEPER, PULSE UP, CO-ORDINATION POOR
10% TO 12%
RESPIRATION FAST & SHALLOW, GIDDINESS, POOR JUDGMENT, LIPS BLUE
8% TO 10%
NAUSEA, VOMITING, UNCONSCIOUS-NESS, ASHEN FACE
6% TO 8%
8 MIN – 100% FATAL, 6 MIN – 50% FATAL, 4-5 MIN – RECOVERY WITH TREATMENT 4%
COMA IN 40 SECS, CONVULSION, RESPIRATION CEASES, DEATH.
19.5% ( MINIMUM)
SAFE LIM IT FOR HUMAN BEING

159. ACCIDENT PREVENTION THROUGH PPE
TYPE
DESIGNED USE
Fresh Air Breathing Apparatus
Oxygen Breathing Apparatus
Compressed Air Breathing Apparatus
To be used in tanks,pits or areas where gas tests show harmful amount of gas,dust,mist,vapour,lack of oxygen
Filter or chemical cartridge respirators
Canister type
Dust respirators
Protection against low concentration of gases,dusts,fumes or mist.

160. FRESH AIR BREATHING APPARATUS
v  Care It
Necessity:
It must be used in all cases when it is necessary to enter an
enclosed area where:
Hydrogen sulphide,carbon monoxide or any other combustible/
toxic gas is present even in slight concentration.
Canister can not be used because the concentration
exceeds the limit for canister.
There is heavy smoke.
There is an oxygen deficiency.

161. COMPRESSED AIR BREATHING APPARATUS
Full duration:
It is the time a BA set is expected to last from the moment
it is started up until the cylinder is exhausted.
Working duration:
it is the time the BA set is expected to last from the time it is started
until the cylinder pressure is reached at which the low pr. Warning
whistle starts to operate.
Safety margin:
it is the time from the moment the whistle starts to sound until the cylinder is exhausted.
In short Working duration = Full duration – Safety margin.
v  Care It

162. Canister type gas mask Limitation & Caution:
The canister is suitable only for small concentration I,e max 20000ppm for toxic & acid gas.For ammonia it is 30000ppm.
Shall not be used inside any enclosed area.
Suitable for limited time period( 12 minutes for full conc.limit)
The canister should be replaced within 6 month or 100 hours of operation once the bottom seal is broken.
v  Care It

163. Dust respirator Limitation & Caution:
It must not be used in closed vessels where there is oxygen deficiency.
Do not wear a respirator,which has been worn by
someone else until it has been sterilized.
Keep the respirator dry.
v  Care It

164. Colour codes of canister as per IS8318/77
Acid gases White
Organic vapours Black
Ammonia gas Green
Carbon monoxide gas Blue
Acid gases & Organic Vap Yellow
Acid gases,ammonia & organic vap - Brown
Acid gas,ammonia,co & Org.vap Red

165. Dust Non respiratory safety devices
Face & Eye protection
Head protection
Hand protection
Foot protection
Body protection
Hearing protection
Safety belts.
v  Care It

166. Selection of eye & face protective equipment
Operation Hazards Recommended Protector
Burning,cutting,gas weld. Sparks,molten metal,harmful rays. Welding goggles
Chemical handling splash,acid burns,fumes clear goggles/face shield.
Elec. Welding spark,intense rays,molten metal welding hood
Furnace operation Glare,heat cobalt glasses/face shield
Grinding flying particles clear goggles /face shield
Laboratory chemical splash,glass breakage clear goggles/face shield
Machining flying particles clear chipper goggles/face shield.
v  Care It

167. IDENTIFICATION OF COLOUR FOR GAS CYLINDER (AS PER GAS CYLINDER RULES 1940)
ACETYLENE (C2H2) - MAROON
AIR GREY
CHLORINE - YELLOW
HYDROGEN - RED
OXYGEN - BLACK
NITROGEN - GREY
AMMONIA - BLACK
CARBONDIOXIDE - BLACK
CARBON MONOXIDE - RED
SULPHUR DIOXIDE - GREEN

168. ACCIDENT REPORTING & INVESTIGATION

169. DEFINITIONS OF TERMS USED
INJURY : ANY BODILY HARM TO ANY PERSON.
MINOR ACCIDENT : ANY INJURY TO A PERSON DURING COURSE OF HIS DUTY ,CAUSING DISABLEMENT FOR A PERIOD OF LESS THAN 48 HRS. IMMEDIATELY AFTER ACCIDENT.
LOSS TIME ACCIDENT : ANY INJURY TO A PERSON DURING COURSE OF HIS DUTY ,CAUSING DISABLEMENT FOR A PERIOD OF 48 HRS OR MORE IMMEDIATELY AFTER ACCIDENT OR LATER AS A EFFECT OF ACCIDENT.
FATALITY: ANY EVENT CAUSING A LOSS OF LIFE.
H1-PO ACCIDENT : AN EVENT THAT HAS THE POTENTIAL TO CAUSE
MAJOR ACCIDENT.
OCCUPATIONAL ILLNESS : ANY ILLNESS, WHICH RESULTS FROM EXPOSURE TO THE WORKING ENVIRONMENT.

170. DEFINITIONS OF TERMS USED
PROPERTY DAMAGE : AN UNPLANNED OR UNDESIRED EVENT WHICH DOES NOT RESULT IN INJURY BUT HAS CAUSED DAMAGE TO PROPERTY/EQUIPMENT TO THE EXTENT OF Rs. 2 LAKS OR MORE.
PROCESS LOSS : AN UNPLANNED OR UNDESIRED EVENT WHICH DOES NOT RESULT IN INJURY BUT RESULTS IN SUBSTANDARD OR DECREASED PRODUCTION TO THE EXTENT OF MORE THAN ONE DAY PLANT SHUTDOWN.

171. ACCIDENT REPORTING SYSTEM
ALL ACCIDENTS ARE TO BE REPORTED HOWEVER
SMALL MAY BE.
SPECIFIC FORMAT TO BE USED FOR REPORTING THE
ACCIDENT
TYPES OF REPORTING FORMATS:
A-I ( INCIDENT REPORT FORM): TO BE FILLED BY THE SUPERVISOR IMMEDIATELY HALF AN HOUR FOR HUMAN INJURY AND 24 HRS FOR OTHER INCIDENCES
A-II ( LOSS TIME ACCIDENT REPORT): TO BE FILLED UP BY THE MEDICAL IN CASE OF HUMAN INJURY WHICH CALLS FOR ABSENCE FROM DUTY.

172. ACCIDENT REPORTING SYSTEM
A-III ( CERTIFICATE OF FITNESS): TO BE FILLED UP BY MEDICAL ON DISCHARGE OF THE INJURED PERSON.
A-IV ( PERMANENT DISABILITY CERTIFICATE): TO BE FILLED UP BY MEDICAL IN CASE OF PERMANENT DISABILITY ARISING DUE TO ACCIDENT.
A-V ( INCIDENT INVESTIGATION REPORT): TO BE FILLED UP BY SUPERVISOR WITHIN 48 HRS.

173. PURPOSE OF INVESTIGATION
TO PROVIDE INFORMATION FOR :
FINDING OUT BASIC CAUSES
IDENTIFYING AREAS FOR CONTROL.
TO ENABLE IMPLEMENTATION OF REMEDIAL ACTIONS.
TO ELIMINATE/REDUCE THE PROBABILITYOF RECURRENCE OF THE EVENT.

174. ANALYSIS OF CAUSES
CLASSIFY THE COLLECTED INFORMATION INTO FIVE STAGES.
LOSSES.
INCIDENTS OR CONTACTS.
IMMEDIATE CAUSES
BASIC CAUSES.
LACK OF CONTROL.
SYSTEMATIC ANALYSIS IS THE CORE OF ACCIDENT INVESTIGATION.

175. REMEDIAL ACTION CONTROL THE BASIC CAUSE TO :
A. LOWER THE PROBABILITY OF OCCURRENCE.
B. REDUCE THE POTENTIAL SEVERITY OF THE INJURY OR DAMAGE.
ACTIONS SHOULD BE
TEMPORARY - EG: GIVING INSTRUCTION.
PERMANENT - TO CORRECT PERSONAL FACTORS OR JOB FACTORS.

176. SUPERVISORS ROLE IN SAFETY

177. DUTIES OF SUPERVISORS IN PROMOTING SAFETY
EACH SUPERVISOR SHALL EXERCISE CLOSE SUPERVISION OVER HIS MANPOWER..
SHALL ENSURE THAT PERSONS WORKING UNDER HIM ARE COMPETENT TO PERFORM THEIR WORK SAFELY.
HE MUST TAKE IMMEDIATE CORRECTIVE ACTION WHENEVER UNSAFE CONDITIONS / PRACTICES ARE OBSERVED.
SUPERVISOR SHALL EXPLAIN IN DETAIL THE PARTICULAR HAZARDS WHERE THE EMPLOYEE IS WORKING AND THE PRECAUTIONS TO BE TAKEN TO ENSURE SAFETY.
HE SHALL DEVELOP SAFETY AWARENESS IN THE MINDS OF ALL EMPLOYEES.
SUPERVISORS SHALL ENSURE THAT THE SAFETY REGULATIONS ARE UNDERSTOOD, THAT ALL HAZARDS ARE ELIMINATED WHEREVER POSSIBLE AND ALL MEANS OF EGRESS/EXIT, STAIRWAYS AND SIMILAR MEANS OF ESCAPE ARE CLEAR, WORKABLE AND THOROUGHLY KNOWN TO ALL HIS MEN.

178. DUTIES OF SUPERVISORS IN PROMOTING SAFETY
HE MUST SET A GOOD EXAMPLE IN KNOWING AND OBSERVING ALL SAFETY RULES AND PRECAUTIONS.
SUPERVISORS SHALL INVESTIGATE AND REPORT THE ROOT CAUSES OF ACCIDENTS THAT TAKE PLACE IN THEIR AREAS.
SUPERVISORS ARE REQUIRED TO MAKE CONTACTS WITH PERSONS WORKING IN ISOLATED PLACES.
BY REGULAR AND SYSTEMATIC INSPECTION, SUPERVISOR SHALL ENSURE THAT ALL TOOLS, EQUIPMENT, MACHINERIES AND PREMISES ARE IN SAFE AND OPERATIVE CONDITIONS.
SUPERVISORS MUST TAKE CORRECTIVE ACTION WHENEVER RULES ARE NOT OBSERVED BECAUSE A SINGLE VIOLATION MAY BECOME A SOURCE OF MAJOR ACCIDENT AND MAY PUT THE SAFETY OF AN INDIVIDUAL OR A GROUP IN JEOPARDY.

179. REFERENCES SAFETY MANUAL ( HQ/ UNITS) PROCESS SAFETY MANUAL (UNITS)
FIRE PROTECTION MANUAL (UNITS)
UNIT OPERATING MANUAL
MATERIAL SAFETY DATA SHEET
OISD STANDARDS
BIS STANDARDS
LOSS CONTROL MANUAL
SEQMS MANUALS
RELEVANT STATUTORY ACTS AND RULES

180. SAFETY MANAGEMENT SYSTEMS
SAFETY OUR FIRST JOB
SAFETY MANAGEMENT SYSTEMS

181. WHY SAFETY IS OUR FIRST JOB
To protect human life
To protect company property
To protect surrounding environment/ community
To efficiently run the business & reduce Losses
To enhance productivity
To build up morale & team spirit
To enhance corporate image

182. Safety Management
In the early stage of industrialization safety was managed through training and following safe procedures, compliance of rules and regulations, etc.
Next stage witnessed enhanced safety feature through technological up-gradation safe processes, safety features in built in design and prescriptive statutory rules.
Finally safety is managed through systems approach. The ‘Cullen Report’, 1990 on Piper Alpha Disaster stressed the need for formal safety management system.

183. Safety Management System
An integrated approach of Management, Leadership Commitment and Coordinated Technical Interventions from concept to commissioning to commercial operations

184. Safety Management Systems
EPA Risk Management Programme
API RP 750 : Management of Process Hazards
CMA (Chemical Manufacturers Association) Systems
CCPS Guidelines for Technical Management of Chemical Process Safety
OSHA - Process Safety Management
OHSAS –18001
OISD

185. Elements of Safety Management Systems
Management Leadership, Commitment and Accountability
Employee Participation
Process safety Information
Process Hazard Analysis
Operating Procedures
Training
Contractors

186. Elements of Safety Management Systems
Pre-commissioning Checks and Audits
Work Permit System
Mechanical Integrity
Incident Investigation
Management of Change
Emergency Planning and Response
Safety Audits
Regulatory Compliance

187. Management Commitment & Leadership
Corporate safety policy
Allocation of resources
Development of systems & guidelines
Performance of systems & guidelines
Nurturing positive safety culture

188. Management Commitment & Leadership
Rewarding outstanding performance
Occupational Health
Compliance with Regulations
Environmental Protection
Community Awareness

189. Employee Participation
Abide by safety rules/regulations
To follow safe operating practices
Actively participate in safety committees
Feed back on unsafe practices and acts
Train co-workers and assist them in performing safely
Help in controlling safety and environmental incidences
Use Personal Protective Equipment (PPE)

190. Process Safety Information
Complete and accurate information about
Process Chemicals
Process Technology
Process Equipment

191. Process Safety Information
Process Chemicals
Physical Properties like vapour pressure, boiling point etc.
Fire & Explosion Hazards like flash point, auto-ignition temperature, explosive limits etc.
Reactive hazards (tendency to react violently)
Health hazard (toxicity)
Corrosive properties

192. Process Safety Information
Process Technology
Written down process description
Process chemistry
Safe Operating limits
P&ID

193. Process Safety Information
Process Equipment
Materials of construction
Design Specifications
Electrical classification

194. Process Hazard Analysis
What - if - analysis
Check-list
Hazard & Operability Studies (HAZOP)
Quantitative Risk Analysis (MCA based)
Strategies to minimise risk
Process safety information provides input for such studies/task

195. Operating Procedures
Comprehensive operation, maintenance & Inspection Manuals
Equipment operation, normal start up and shut downs, emergency handling procedures
Interlocks and safe shut-down instrument functions & its special features
Contains work permit system, equipment hand-over, fire protection/fighting facilities etc.

196. Training
Employees, contractors, security personnel, Truck drivers/khalasis
Core Safety training
Skill training
Refresher training
Use of modern training aids - simulators

197. Training Training on operating instructions
Emergency response training
Skill of trainers
Training effectiveness
Change of assignment/retraining
Certification

198. Pre-commissioning Safety checks & Audit
Carried out by multi disciplinary team on a well structured check list
To ensure construction as per design
To ensure compliance with regulations
To ensure proper documentation, operating procedures, training

199. Pre-commissioning Safety checks & Audit
To ensure that all protections are provided, tested and put in place
Work permit system in place
All personnel protective equipment provided for ready use.

200. Mechanical Integrity The objective is to ensure
Reliable and safe operation
Higher equipment life
Higher on-stream factor

201. Mechanical Integrity Condition Monitoring
Preventive /Predictive Maintenance
Residual Life Assessment
Periodic Testing of Relief Valves, Interlocks, Alarms, shut down systems etc.
Documentation of monitored data to guide corrective actions
Only nominated officers approve by-passing of TRIPS/Interlocks etc. Restoration on top priority.

202. Management of Change
Procedure for evaluating potential impact, authorising and control
Proposed changes are reviewed by various functions/departments
Operating/maintenance personnel are imparted training
Documents are updated and changes are communicated to all concerned
Same control is exercised for temporary as well as permanent changes

203. Safety Audit To check and affirm System Effectiveness
Done on structured check list by Multi Disciplinary Teams
Internal Audit - Every Year
External Audit (once in 3 years) & Surprise Audit (once in a year) by OISD
Implementation of recommendations
Review

204. Statutory Compliance The Factories Act, 1948 The Petroleum Rules, 1976
The Gas Cylinder Rules, 1981
The SMPV (U) Amendment Rules, 2000
The MSIHC Rules, 2000
The EP Act, 1986
and other relevant rules like Indian Electricity Act, Boiler Regulations, Central Motor Vehicle Rules etc. to be followed.

205. MISCONCEPTION ON SAFETY
ACCIDENTS HAPPEN – THEY ARE INEVITABLE.
IF A PERSON IS DESTINED TO MEET WITH AN ACCIDENT NO MORTAL EFFORTS CAN SAVE HIM.
WHERE THERE IS HUGE MACHINERIES AND FAST MOVING PRODUCTION LINES ACCIDENTS ARE INEVITABLE.
SAFETY RULES ARE FOR NEW COMERS AND NOVICES.
A WILLING WORKER WILL MEET WITH AN ACCIDENT – NOT THE IDLER.
IT NEEDS A REAL HE-MAN TO FACE IT.
SAFETY RULES ARE MANAGEMENT’S BABY; WHY SHOULD BOTHER.
MAINTAINING SAFETY IS A MANAGERIAL FUNCTION.

206. Risk Management
206

207. Risk Management
From Cradle ...
… to Grave
207

208. Risk Management “Public” assessment of Risk
Intuitive
Yes/No
Safety
Is it or Isn’t it
Discrete events
Personal consequences
It matters how we die
“Expert” assessment of Risk
Scientific
Probabilistic
Acceptable Risk
Changing knowledge
Comparative risk
Population averages
A death is death
208

209. Control: HIERARCHY OF CONTROL Hierarchy of Control:
The measures we take to eliminate or reduce the risk to an acceptable level.
Hierarchy of Control:
The order in which controls should be considered
When selecting methods of controlling a risk.
209

210. HIERARCHY OF CONTROL Elimination Substitution Isolation
Engineering Controls
Administrative Controls
Provide Personal Protective Equipment .
210

211. HIERARCHY OF CONTROL ELIMINATION
The Best method of dealing with a hazard is to
eliminate it.
Once the hazard has been eliminated the
potential for harm has gone.
211

212. HIERARCHY OF CONTROL SUBSTITUTION
This involves substituting a dangerous process
or substance with one that is not as dangerous.
This may not be as satisfactory as elimination as
there may still be a risk (even if it is reduced).
212

213. HIERARCHY OF CONTROL ISOLATION
Separate or isolate the hazard from people.
This method has its problems in that the hazard has
not been removed.
The guard or separation device is always at risk of being
removed or circumvented.
213

214. HIERARCHY OF CONTROL ADMINISTRATION
Administrative solutions usually involve modification
of the likelihood of an accident happening.
This can be done by reducing the number of people
exposed to the danger reducing the amount of time
exposed and providing training to those people who
are exposed to the hazard.
214

215. HIERARCHY OF CONTROL PERSONAL PROTECTIVE EQUIPMENT
Provision of personal protective equipment should only
be considered when all other control methods are
impractical, or to increase control when used with another
method higher up in the Hierarchy of Control.
215

216. MONITORING AND REVIEW KEY POINT
A review follow-up is always essential.
Review is an important aspect of any risk
Management process.
It is essential to review what has been done to
Ensure that the controls put in place are effective.
216

217. The Risk Management Process
The total procedure associated with
- Identifying a HAZARD,
- Assessing the RISK,
- Putting in place CONTROL MEASURES,
AND REVIEWING THE OUTCOMES.
217

218. Hazard Identification
218

219. Risk Assessment
219

220. The risk management process is an
CONCLUSION
Hazard identification, risk assessment, control and review
is not a task that is completed and then forgotten about.
Hazard identification should be properly documented even
in the simplest of situations.
Risk assessment should include a careful assessment
of both LIKELIHOOD and CONSEQUENCE.
Control measures should conform to the recommendations
of the hierarchy of control.
The risk management process is an
ON GOING ONE
220

221. Thank You

222. PIELINE TRANSPORTATION SYSTEM
Pipeline is a network of pipes used for the transportation of materials, in liquid form, from one place to another. It requires one storage area and one pumping unit for the material to be transported from one location to the another.
Generally, Cross-country pipelines are laid underground and used for transporting raw material or oil as well as finished products from one locations. In this system, block valves are given at a maximum distance of 75 kms so as to restrict the flow during emergency situation. Along with the pipeline a set up of communication system is provided for efficient communication during emergency any maintenance activity.
The emergencies in pipeline may one of the following:
Leak.
Leak with Fire.
Burst.
Burst with Fire.

223. SAFETY SYSTEM IN PIELINES
In pipeline installations various safety systems are adopted to ensure the safe movement of the material. The measures adopted to ensure the safety are as follows:
Maximum allowable operating pressure in the pipeline.
Pressure relief valves.
Block Valves for dividing the whole pipeline into various sections.
Station limit valve.
High level tripping devices on discharge side of the pumping unit.
Low level tripping devices on suction side of the pumping unit.
Alarm for high level in the storage tanks.
Data monitoring through SCADA system.
Leak detection system.
Manual call points in the installation.
Emergency shut down.
Fix as well as mobile fire fighting and protection system for the installation.

224. JETTY INSTALLATIONS
Jetties are the locations near the ports where loading and / or unloading of the material takes place from port to ships and vice-versa. The jetties are basically of two types:
RORO Jetty – Roll On Roll Off – Jetty used for loading and unloading of goods.
LOLO Jetty – Load On Load Off – Jetty used for lading and unloading of Petroleum products.
SAFETY SYSTEM AT JETTIES:
Jetty Installations are provided with inbuilt protection facilities including the following:
Auto shut-off system at the unloading arm during emergency.
Water hydrant network.
Fixed water-cum-foam monitors of high range.
Manual Call Points.
Portable Fire Extinguishers.

225. FIRE HYDRANT NETWORK DISTRIBUTION NETWORK:
Network shall be laid in closed loops as far as possible to ensure multi-directional flow in the system. Isolation valves shall be provided in the network to enable isolation of any section of the network without affecting the flow in the rest. The isolation valves shall be normally located near the loop junctions. Additional valves shall be provided in the segments where the length of the segment exceeds 300 mts.
FIRE HYDRANTS:
Fire hydrants shall be provided in the network to ensure protection to all the facilities. The location of the hydrants shall be carefully decided keeping in view the easy accessibility. The maximum distance between two hydrants, however, shall not exceed 30 mtrs around hydrocarbon storage and hazardous areas and 45 mtrs in other areas. Each hydrant shall have two outlets inclined towards the ground. The outlets shall be of female instantaneous type having a standard size of 63.5 mm conforming to BIS.
HEADER PRESSURE:
The fire water system shall be designed for a minimum residual pressure of 7.0 kg/cm2 g at the hydraulically remotest point of application at the designed flow rate at that point.
The fire water network shall be kept pressuriSed at minimum 7.0 kg/cm2 gat all the time. In existing refineries, this shall be achieved in a phased manner.