PROJECT

ON
STUDY OF POWER PLANT LAYOUT
WITH BRIEF PROCESS
INFORMATION AND FIRE RISK
ANALYSIS

FOR ADVANCE DIPLOMA IN INDUSTRIAL SAFETY

SESSION- 2019-2021
DEVELOPED BY- Mr. CHANDAN MONDAL
3 rd SEMESTER
ROLL- DSSPE/IS (P)

DURGAPUR SOCIETY FOR SAFETY AND

PROFESSIONAL EDUCATION
UNDER
WEST BENGAL STATE COUNCIL OF TECHNICAL
EDUCATION
 Acknowledgement
I express my deepest appreciation to Mr. T. R Goswami (Assistant
General Manager in D.S.P) for his expert guidance in the course of
preparation of this project on Fire Risk analysis in Power Plant.
Without which it would not have been possible to submit this project
in a presentable manner. His passion, patience, diligence and wisdom
always influence me. He is truly my professor, mentor and also a
good friend.

My special thanks go to Dr. N. C Bhattacharjee; Principal of

Durgapur Society for Safety and Professional Education. He is
such a nice person with great respect for his students. His thoughts
and knowledge in building information modelling greatly inspired the
topic of “Safety”.

I also thank Mr. Golam Mowla for providing study material and
books from the Library, and the class mates who helps me a lot in the
making of the project.

CHANDAN MONDAL
3rd
SEMESTER
Roll: DSSPE/IS
(P)/S3

No:0015
Student of Diploma in Industrial
safety
(2019-
2021)
 DURGAPUR SOCIETY FOR
SAFETY &
PROFESSIONAL
EDUCATION

INDEX
SL. NO Description
01 Acknowledgement
02 Introduction
03 Thermal Power Plant
04 Layout of Power Plant
05 Brief description of plant process
06 Hazard identification risk & risk reduction strategies
07 Short Definition
08 Classification of Fire
09 Maintenance of Extinguisher
10 Fixed Fire Fighting system
11 Automatic fire fighting system
12 B.A Set
13 U.N Classification
14 Fire Alarm System
15 Determining fire hazard
16 Checklist of fire prevention
17 On-site emergency plan
18 Conclusion
 THERMAL POWER PLANT
A generating station which converts heat energy of coal combustion into electrical energy is
known as a steam power station.
A steam power station basically works on the Rankine cycle. Steam is produced in the boiler
by utilizing the heat of coal combustion. The steam is then expended in the prime mover and
is condensed in a condenser to be a fed into the boiler again. The steam turbine drives the
alternator which converts mechanical energy of the turbine into the electrical energy. The
type of power station is suitable where coal and water are available in abundance and a large
amount of electric power is to be generated.

Thermal Power Plant Layout and Operation

Thermal Power Plant Lay out:

The above diagram is the lay out of a simplified thermal power plant and the below is also
diagram of a thermal power plant.
The above diagram shows the simplest arrangement of coal fired (Thermal) power plant.
Main parts of the plant are

1. Coal conveyor 2. Stoker 3. Pulverize 4. Boiler 5. Coal ash 6. Air preheated 7. Electrostatic
precipitator 8. Smoke stack 9. Turbine 10. Condenser 11. Transformers 12. Cooling towers
13. Generator 14. High - voltage power lines

Basic Operation: A thermal power plant basically works on Rankine cycle.

Coal conveyor: This is a belt type of arrangement. With this coal is transported from coal
storage place in power plant to the place nearby boiler.
Stoker: The coal which is brought nearby boiler has to put in boiler furnace for combustion.
This stoker is a mechanical device for feeding coal to a furnace.
Pulverize : The coal is put in the boiler after pulverization. For this pulverize is used. A
pulverize is a device for grinding coal for combustion in a furnace in a power plant.

Types of Pulverizes
Ball and Tube Mill Ball mill is a pulverize that consists of a horizontal rotating cylinder, up
to three diameters in length, containing a charge of tumbling or cascading steel balls,
pebbles, or rods.
Tube mill is a revolving cylinder of up to five diameters in length used for fine pulverization
of ore, rock, and other such materials; the material, mixed with water, is fed into the chamber
from one end, and passes out the other end as slime.

Ring and Ball

This type consists of two rings separated by a series of large balls. The lower ring rotates,
while the upper ring presses down on the balls via a set of spring and adjuster assemblies.
Coal is introduced into the centre or side of the pulverize (depending on the design) and is
ground as the lower ring rotates causing the balls to orbit between the upper and lower rings.
The coal is carried out of the mill by the flow of air moving through it. The size of the coal
particles released from the grinding section of the mill is determined by a classifier separator.
These mills are typically produced by B&W (Babcock and Wilcox).

Boiler: Now that pulverized Coal is put in boiler furnace. Boiler is an enclosed vessel in
which water is heated and circulated until the water is turned in to steam at the required
pressure.
Coal is burned inside the combustion chamber of boiler. The products of combustion are
nothing but gases. These gases which are at high temperature vaporize the water inside the
boiler to steam. Sometimes this steam is further heated in a super heater as higher the steam
pressure and temperature the greater efficiency the engine will have in converting the heat in
steam in to mechanical work. This steam at high pressure and temperature is used directly as
a heating medium, or as the working fluid in a prime mover to convert thermal energy to
mechanical work, which in turn may be converted to electrical energy. Although other fluids
are sometimes used for these purposes, water is by far the most common because of its
economy and suitable thermodynamic characteristics.
Classification of Boilers

Boilers are classified as

Fire tube boilers: In fire tube boilers hot gases are passed through the tubes and water
surrounds these tubes. These are simple, compact and rugged in construction. Depending on
whether the tubes are vertical or horizontal these are further classified as vertical and
horizontal tube boilers. In this since the water volume is more, circulation will be poor. So
they can't meet quickly the changes in steam demand. High pressures of steam are not
possible, maximum pressure that can be attained is about 17.5kg/sq cm. Due to large
quantity of water in the drain it requires more time for steam raising. The steam attained is
generally wet, economical for low pressures. The out of the boiler is also limited.

Water tube boilers: In these boilers water is inside the tubes and hot gases are
outside the tubes. They consists of drums and Tubes. They may contain any number of
drums (you can see 2 drums in fig).Feed water enters the boiler to one drum (here it is drum
below the boiler).This water circulates through the tubes connected external to drums. Hot
gases which surround these tubes will convert the water in tubes in to steam. This steam is
passed through tubes and collected at the top of the drum since it is of light weight. So the
drums store steam and water (upper drum). The entire steam is collected in one drum and it is
taken out from there (see in layout fig). As the movement of water in the water tubes is high,
so rate of heat transfer also becomes high resulting in greater efficiency. They produce high
pressure, easily accessible and can respond quickly to changes in steam demand. These are
also classified as vertical, horizontal and inclined tube depending on the arrangement of the
tubes. These are of less weight and less liable to explosion. Large heating surfaces can be
obtained by use of large number of tubes. We can attain pressure as high as 125 kg/sq cm and
temperature from 315 to 575 centigrade.
Super heater: Most of the modern boilers are having super heater and reheated
arrangement. Super heater is a component of a steam-generating unit in which steam, after it
has left the boiler drum, is heated above its saturation temperature. The amount of superheat
added to the steam is influenced by the location, arrangement, and amount of super heater
surface installed, as well as the rating of the boiler. The super heater may consist of one or
more stages of tube banks arranged to effectively transfer heat from the products of
combustion. Super heaters are classified as convection, radiant or combination of these.

Re-heater: Some of the heat of superheated steam is used to rotate the turbine where it
loses some of its energy. Re heater is also steam boiler component in which heat is added to
this intermediate-pressure steam, which has given up some of its energy in expansion
through the high-pressure turbine. The steam after reheating is used to rotate the second
steam turbine (see Layout fig) where the heat is converted to mechanical energy. This
mechanical energy is used to run the alternator, which is coupled to turbine, there by
generating electrical energy.

Cooling Towers: The condensate (water) formed in the condenser after condensation is
initially at high temperature. This hot water is passed to cooling towers. It is a tower- or
building-like device in which atmospheric air (the heat receiver) circulates in direct or
indirect contact with warmer water (the heat source) and the water is thereby cooled (see
illustration). A cooling tower may serve as the heat sink in a conventional thermodynamic
process, such as refrigeration or steam power generation, and when it is convenient or
desirable to make final heat rejection to atmospheric air. Water, acting as the heat-transfer
fluid, gives up heat to atmospheric air, and thus cooled, is re-circulated through the system,
affording economical operation of the process.

Two basic types of cooling towers are commonly used. One transfers the heat from warmer
water to cooler air mainly by an evaporation heat-transfer process and is known as the
evaporative or wet cooling tower.
Evaporative cooling towers are classified according to the means employed for producing air
circulation through them: atmospheric, natural draft, and mechanical draft. The other
transfers the heat from warmer water to cooler air by a sensible heat-transfer process and is
known as the non-evaporative or dry cooling towers.

Non-evaporative cooling towers are classified as air-cooled condensers and as air-cooled heat
exchangers, and are further classified by the means used for producing air circulation
through them. These two basic types are sometimes combined, with the two cooling
processes generally used in parallel or separately, and are then known as wet-dry cooling
towers.

Economizer: Flue gases coming out of the boiler carry lot of heat. Function of
economizer is to recover some of the heat from the heat carried away in the flue gases up the
chimney and utilize for heating the feed water to the boiler. It is placed in the passage of flue
gases in between the exit from the boiler and the entry to the chimney. The use of
economizer results in saving in coal consumption, increase in steaming rate and high boiler
efficiency but needs extra investment and increase in maintenance costs and floor area
required for the plant. This is used in all modern plants. In this large number of small
diameter thin walled tubes are placed between two headers. Feed water enters the tube
through one header and leaves through the other. The flue gases flow outside the tubes
usually in counter flow.

Air pre-heater: The remaining heat of flue gases is utilized by air pre-heater. It is a
device used in steam boilers to transfer heat from the flue gases to the combustion air before
the air enters the furnace. Also known as air heater; air-heating system. It is not shown in the
lay out. But it is kept at a place nearby where the air enters in to the boiler.
The purpose of the air pre-heater is to recover the heat from the flue gas from the boiler to
improve boiler efficiency by burning warm air which increases combustion efficiency, and
reducing useful heat lost from the flue. As a consequence, the gases are also sent to the
chimney or stack at a lower temperature, allowing simplified design of the ducting and stack.
It also allows control over the temperature of gases leaving the stack (to meet emissions
regulations, for example).After extracting heat flue gases are passed to electrostatic
precipitator.
Electrostatic precipitator: It is a device which removes dust or other finely divided
particles from flue gases by charging the particles inductively with an electric field, then
attracting them to highly charged collector plates. Also known as precipitator. The process
depends on two steps. In the first step the suspension passes through an electric discharge
(corona discharge) area where ionization of the gas occurs. The ions produced collide with
the suspended particles and confer on them an electric charge. The charged particles drift
toward an electrode of opposite sign and are deposited on the electrode where their electric
charge is neutralized. The phenomenon would be more correctly designated as electrode
position from the gas phase.
The use of electrostatic precipitators has become common in numerous industrial
applications. Among the advantages of the electrostatic precipitator are its ability to handle
large volumes of gas, at elevated temperatures if necessary, with a reasonably small pressure
drop, and the removal of particles in the micrometer range. Some of the usual applications
are: (1) removal of dirt from flue gases in steam plants; (2) cleaning of air to remove fungi
and bacteria in establishments producing antibiotics and other drugs, and in operating rooms;
(3) cleaning of air in ventilation and air conditioning systems; (4) removal of oil mists in
machine shops and acid mists in chemical process plants; (5) cleaning of blast furnace gases;
(6) recovery of valuable materials such as oxides of copper, lead, and tin; and (7) separation
of retile from zirconium sand.

Smoke Stack: A chimney is a system for venting hot flue gases or smoke from a boiler,
stove, furnace or fireplace to the outside atmosphere. They are typically almost vertical to
ensure that the hot gases flow smoothly, drawing air into the combustion through the
chimney effect (also known as the stack effect). The space inside a chimney is called a flue.
Chimneys may be found in buildings, steam locomotives and ships. In the US, the term
smokestack (colloquially, stack) is also used when referring to locomotive chimneys. The
term funnel is generally used for ship chimneys and sometimes used to refer to locomotive
chimneys. Chimneys are tall to increase their draw of air for combustion and to disperse
pollutants in the flue gases over a greater area so as to reduce the pollutant concentrations in
compliance with regulatory or other limits.

Generator: An alternator is an electromechanical device that converts mechanical

energy to alternating current electrical energy. Most alternators use a rotating magnetic field.
Different geometries - such as a linear alternator for use with sterling engines - are also
occasionally used. In principle, any AC generator can be called an alternator, but usually the
word refers to small rotating machines driven by automotive and other internal combustion
engines.

Transformers: It is a device that transfers electric energy from one alternating-current

circuit to one or more other circuits, either increasing (stepping up) or reducing (stepping
down) the voltage. Uses for transformers include reducing the line voltage to operate low
voltage
devices (doorbells or toy electric trains) and raising the voltage from electric
generators so that electric power can be transmitted over long distances. Transformers act
through electromagnetic induction; current in the primary coil induces current in the
secondary coil. The secondary voltage is calculated by multiplying the primary voltage by
the ratio of the number of turns in the secondary coil to that in the primary.
FIRE HAZARDS IDENTIFIED
It is also recognized that Earring Power Station has detailed manifests of all dangerous goods
and emergency management and reporting systems are in place for the entire Station site as
required by Section 6A of the Occupational Health and Safety Regulation 2000 and the
requirements of the NSW Work Cover Dangerous Goods Unit and the NSW Fire Brigades.

HAZARD IDENTIFICATION AND RISK REDUCTIONS TRATEGIS

The main hazards associated with the upgrade project are related to the handling of
flammable gases (hydrogen) and combustible liquids including turbine lubrication oils and
greases, transformer insulating oils and boiler burner start up distillate. Major storages of
these products are in sufficient quantities to cause a major explosion or fire.
Minor quantities of materials as may be found in additives, cleaning products and
miscellaneous waste such as rag and paper have not been specifically identified.
Main ignition sources associated with the upgrade areas are:
Heat Energy
Steam turbines / boiler burner areas
Steam pipes and control equipment
Hydraulics equipment
Electrical control equipment
Electrical Energy
Cables
Drive motors/ generators
Cable arcing / insulation failures / earth faults
Mechanical Energy
Hot work
Accumulation of combustibles around rotating equipment
High pressure oil lines
Aircraft crashes (highly unlikely)
Chemical
Hydrazine / chemical storages (leaks, tank failures)
Human
Failure to follow standard operating procedures
Arson, terrorist attack, green lobby or disgruntled employees
Uncontrolled smoking
Environment
Lightning
Bushfires / ember attack (Boiler fuel oil tanks only)

Turbine Generator Fire Hazards Identification

The predominant mode in which a hazardous incident may be generated is associated with a
combustible liquid or flammable gas leak contacting hot Turbine operating surfaces e.g.
bearings, steam and throttle control valves.
Lubricating Oils
The largest hazard associated with the turbine generator is the lubricating oils and associated
piping systems equipment which convey, store and process the oil. Turbine lubricating oils
have a flash point of approximately 200 degrees C.
Turbine bearings present a significant fire risk particularly if a bearing on the steam high
pressure end fails due to a seal failure or turbine severe vibration. Under severe vibration
conditions oil can be released from a number of bearings and a fire can result if the oil
contacts uninsulated steam piping of controls. These uninsulated areas can have operating
temperatures of up to 200 degrees C.
Fire resistant Hydraulic Fluid
Fire resistant hydraulic fluid is to be used for the new throttle valve upgrade. This product
has a flash point of around 550 degrees C and will combust if subjected to temperatures
above this level and the product can decompose producing carbon monoxide, organic
decomposition products and phosphoric oxides. The product is also a marine pollutant.
Specialized fire fighting procedures are required to reduce the risk to fire fighters.
Hydrogen Gas
Hydrogen gas us used as the coolant for the generator. When mixed with air, it has a
flammability range of 4% to 75%. Note: Hydrogen is lighter than air odorless and burns with
a colorless flame.
The hydrogen gas in the generator, associated supply pipe work and control equipment
presents both explosion and fire hazards. Although its wide flammability range and high
burning rate accentuate these hazards, its low ignition energy, low heat of combustion on a
volume basis and its low thermal radiation level exert counteracting influences in many
instances.
Because of its low ignition energy, rather small heat producing sources such as friction and
static generation often cause hydrogen ignitions to self extinguish when the gas is released at
high pressure.
Hydrogen is a much greater risk when released at low pressure and if it is not ignited can
accumulate in surrounding generator structures. When contact is made with an ignition
source there is a risk of a fire or explosion.
Electrical Cables and Equipment
Electrical cables and equipment installed adjacent or below turbine generators are not
normally the cause of large fires however they do present a secondary ignition source and
PVC cables (particularly when grouped on vertical cable trays) can propagate fire in
vertically laid bundles at a velocity of 20metres/min.
PVC cables do not only propagate fire by they also develop dense black smoke which can
contain large amounts of acid gas (HCL) combining with water to create hydrochloric acid (1
kg of soft PVC containing 35% chlorine, emits 360 grams HCL gas dissolving to 1 liter
concentration of Hydrochloric Acid) The Hydrochloric Acid carried by thermal draft can
reach distant areas depositing on all surfaces. On metal parts corrosion occurs quickly,
causing irreparable destruction. Even reinforced concrete can be damaged.
Boiler Fire Hazards Identification
The main Boiler fire hazard in which a hazardous incident may be generated is associated
with fire occurrences around boiler burner, wind box areas caused by fuel oil or pulverized
coal used for boiler ignition igniting external to the main boiler. Main causes of fires around
these areas are pulverized coal or oil leakages around burners or failure of fuel lines
contacting hot boiler face surfaces.
Pulverized Coal
Fires involving pulverized coal usually result from leaks at the main boiler igniters and result
from contact with the hot boiler face. Fires have also occurred from incorrect operation of
boiler air controls where explosion have been reported.
Fuel Oil
The initial boiler start-up uses fuel oil with an ignition temperature of around 79 degrees to
pre-heat the furnace before the pulverised fuel can be introduced. Incorrectly installed fuel
oil guns, oil leaks around oil lines causing oil to contact hot burner face areas can result in oil
ignition outside the boiler and in more serious leaks three dimensional fires running down
the face of the boiler.
Generator Transformer Fire Hazards
The main causes of transformer fires are ingress of impurities into the insulating oil (water)
or failure of the transformer insulation around the internal windings. Fires have also been
reported resulting from electrical arcing around external switchgear or failure of oil filled
transformer bushings.
"Extinguisher rating" means the numerical rating given to an extinguisher which indicates
the extinguishing potential of the unit based on standardized tests developed by
Underwriters' Laboratories, Inc.
“Fire brigade" (private fire department, industrial fire department) means an organized
group of employees who are knowledgeable, trained, and skilled in at least basic fire fighting
operations.
"Fixed extinguishing system" means a permanently installed system that either extinguishes
or controls a fire at the location of the system.
"Incipient stage fire" means a fire which is in the initial or beginning stage and which can
be controlled or extinguished by portable fire extinguishers, Class II standpipe or small hose
systems without the need for protective clothing or breathing apparatus.
"Interior structural fire fighting" means the physical activity of fire suppression, rescue or
both, inside of buildings or enclosed structures which are involved in a fire situation beyond
the incipient stage.
"Sprinkler system" means a system of piping designed in accordance with fire protection
engineering standards and installed to control or extinguish fires. The system includes an
adequate and reliable water supply, and a network of specially sized piping and sprinklers
which are interconnected. The system also includes a control valve and a device for actuating
an alarm when the system is in operation.

What is FIRE?
FIRE is a chemical combustion reaction with evaluation of heat or light.

Fire Tetrahedron
• Basic components of a fire are:
– fuel
– source of ignition
– oxygen
– process of combustion
• Commonly referred to as the "fire tetrahedron"
Stage / Phase of fire
1. Incipient Stage. - A) Invisible Smoke. B) Smoke.
2. Smothering Stage.
3. Flame.
4. Heat.
5. Hazard (if heat cannot be control).
Classification of Fire
Fire is a chemical reaction involving the rapid oxidation or burning of a fuel. It needs four
elements to occur as illustrated below in the tetrahedron. This is described by the following
illustration:
The first component of the tetrahedron is fuel. Fuel can be any combustible material such as:
solid (such as wood, paper, or cloth), liquid (such as gasoline) or gas (such as acetylene or
propane). Solids and liquids generally convert to gases or vapours before they will burn.
Another component of the tetrahedron is oxygen. Fire only needs an atmosphere with at least
16% oxygen.
Heat is also a component of the tetrahedron. Heat is the energy necessary to increase the
temperature of the fuel source to a point in which sufficient vapours are emitted for ignition
to
occur.
The final side of the tetrahedron represents a chemical chain. When these components are
brought together in the proper conditions and preparations, fire will develop. Take away any
one of these elements, and the fire cannot exist or will be extinguished if it was already
burning.
Fires are classified into four groups according to sources of fuel: Class A, B, C, and D based
on the type of fuel source. Table 1 below describes the classifications of fire which can be
used in making hazard assessment.

Class A Ordinary combustible materials such as paper, wood,

Cloth and some rubber and plastic materials.

Class B Flammable or combustible liquids, flammable gases,

Greases and similar materials, and some rubber and
Plastic materials.

Class C Energized electrical equipment and power supply

Circuits and related materials.

Class D Combustible metals such as magnesium, titanium,

Zirconium, sodium, lithium and potassium.
Portable or movable apparatus used to put out a small fire by directing onto it a substance
that cools the burning material, deprive the flame of oxygen or interferes with the chemical
reaction occurring in the flame. They are intended as the 1st line of defence against fires of
limited size.

Extinguishing Agent
A material used to control/terminate a fire by cooling the material in the combustion process,
obstructing the supply of oxygen to the combustion process, or chemically inhibiting the
combusting process.

Extinguishing Media of Fire

1. Water Extinguisher.
2. Foam Extinguisher.
3. CO2 Extinguisher.
4. DCP (Dry Chemical Powder) Extinguisher.

Class of Fire Source of Fire Extinguishing Media

Class A Solid Particles Water
(Coal, Rubber, Jute,
Wood)
Class B Inflammable Liquid Foam
(Acid, Alkali, Petrol,
Diesel)
Class C Gas CO2
(Inflammable Liquid
(Acid, Alkali, Petrol,
Diesel)
Class D Special Metal DCP
(Mg, Al, Ni, Fe)

FIRE AND FIRE PROTECTION

How to use a Fire Extinguisher
Simply follow the following steps “P-A-S-S”

P – Pull the pin

Pull the Pin at the top of the extinguisher

A – Aim the nozzle low Aim the nozzle or the outlet towards the base of the fire. Some hose
assemblies are clipped to the body of the extinguisher, and then release the hose and point.
S – Squeeze the handle, lever
Squeeze the handle, lever to release the extinguishing agent.
In some cases valves are present. Before approaching the fire try a short burst.

S – Sweep from side to side at the base of the fire until it is out. After fire is doused,
watch for the smoldering hot spots and possible re-flash. Put off the fire completely.

Method of Extinguishment
1. Cooling
2. Smothering
3. Starvation
Safety Precautions for Maintenance of Extinguisher
While opening any extinguisher.
(a)Ensure that there is no residential pressure in any hose or nozzle.
(b)Unscrew the cap or valve assembly slowly for 2 or 3 turns to allow any residential
pressure to escape via the vent hole.
(c)Do not depend on pressure gage (Stored pressure type) to verify the pressure.
(d)If pressure is not released after unscrewing the cap then do not unscrew it further - sudden
release of pressure may eject parts, cap assembly or the contents of the extinguisher.
(e)The valves of co2 extinguisher /gas cartridge extinguisher should not be attempted to be
removed.
(f)Dry powder extinguisher should be opened only in the driest condition & for minimum
time to minimize the effect of moisture on it. Moisture cause caking of the powder.
(g)Mixing of different types of powder should be avoided as it may cause chemical making.
(h)All sealing component should be cleaned & properly lubricated to prevent leakage after
recharge.
(i)Never connect a stored pressure extinguisher to be charged directly to the high pressure
source.
(j)Storage of recharge material for long periods should be avoided.
Selection of Location
1. To be placed in conspicuous position & shell be readily accessible for immediate use.
2. As near as possible to exits or stairs with out hindering the escape routes.
3. Not to travel more than 15m from the site of fire to reach the extinguisher.
4. If special risk is contained in a confined space ,extinguisher to be installed outside that
space.
5. Wall mounted extinguisher – bottom 1m above ground level.
6. Necessary to construct suitable cover/shade to protect extinguisher.
7. Extinguisher should not be placed in the open from excessive heat & cold as well as from
corrosive environment.

FIXED FIRE FIGHTING SYSTEM (WATER BASED)

FIRE HYDRANT SYSTEM

1. Dry Riser.
2. Wet Riser.
3. Dry cum Wet Riser.
4. Yard Hydrant.
5. Automatic Water Sprinkler.
6. Water Spray Projector.
7. City Fire Fighting Water Supply.

DRY RISER
Dry riser are suitable in some buildings not more than 61mts.in height, where prompt fire
brigade help is available and where fire brigade is located within a distance of 8km.from the
building and has easy access thereto unimpeded by railway level crossing and traffic
congestion. A satisfactory supply of water shall always be available through the town mains
or a ground/underground tank. Dry riser shall be installed only in consultation with the
appropriate authority and their approval of the scheme.

Design Parameter
1. Each riser serves area not more than 930 sq.mt.
2. Riser should be located at easily approachable location.
3. Riser should be of 100mm internal dia. For buildings having ht. up to 46mts. And
150mm for buildings having ht. between 46mts. To 61mts.
4. Fire brigade breaching connection with instantaneous male inlet 2*65mm.for each
100mm.dia.riser and 4*65mm.for each150mm.dia.riser.
5. Fire brigade inlet are fixed on an external wall at 1mt.above ground level, stand
within
12mts.of distance from riser.
6. Inlet are enclosed in a wall box with wired glass front marked as “FIRE BRIGADE
DRY MAIN INLET”.
7. A 65mm. instantaneous female outlet should be provided at 1mts.height from floor
level on each floor.
8. The outlet must meet the requirement at the local Fire authority and Fire Brigade.
9. An air release valve is fitted at the top of each riser to release compressed air during
pumping operation.
 10.Each dry riser must be electrically earthed by a direct earth
connection.

AUTOMATIC WATER SPRINKLER SYSTEM

Water is a cheapest and readily and naturally available means of fire extinguishing. It has
four times more thermal conductivity then air. With the help of automatic sprinkler system in
less quantity of water more area can be extinguished. In this process water is sprayed in fine
droplets. In this process the surrounding space is filled with fine droplet. Due to this percent
of oxygen in the surrounding area goes down and temperature also goes down. This two
aspect help in extinguishing the fire. Thus automatic water sprinkler system gives a facility
to discharge water automatically in sufficient density to extinguish the fire.

TYPES OF AUTOMATIC SPRINKLER SYSTEM

1. Wet type sprinkler system.

2. Dry type sprinkler system.

WET TYPE SPRINKLER SYSTEM

This type of system is used, where temperature of water , inside the piping network, is
maintained above freezing point of water. In this system the piping network is fully charged
with water at required pressure. As soon as sprinkler heads actuate, discharge of water start
in form of spray.
Alarm check valve and water flow detector are installed in the system to actuate local and
remote alarms.

B.A Set
i) Atmospheric Type
(ii) Self Contained type
(a)Closed Circuit (b) Open Circuit
E.g. Proto, Salvos. E.g. Drager.

Respiration
Breathing or respiration is a spontaneous action performed by the human body some 15-30
times every minute. When at rest the body requirement are comparatively low and air is
sucked into & out of the lungs by breathing a rate 15-18 times/minute. When more energy is
exerted either through work excitement, the breathing rate is increased. i.e. 30 times/minute.
At rest ,about 30 inch3(1/2 it apox) air are normally inhaled at each breath & about the same
quality is exhaled – this amount is known as Tidal Air. By taking a deep breath a further 120
inch3 may be taken in making a total of 150 inch3 – this is known as Inspiratory Rescue.
On subsequent deep exhalation this may be increased by further 100 inch3 called the
Expiratory Rescue volume and the total exhalation as about 250 inch³. Thus the total exhaled
is known as the Vital Capacity & varies with different people.

Capacity of Cylinder Net Weight Stored Pressure

1200 lit. air 13 kg 132 atm
1800 lit. air 17 kg 200 atm
2250 lit air 14.5 kg 200 atm
Testing of B.A
1. General Checking / Pre-entry Test.
(i)Visual inspection of all assembly parts.
(ii)Air should be more than 80% i.e.160 hrs.
(iii)Fall mask must be air tight check suffocation by closing the valve after doing.

2. High Pressure Test.

This text is used to find the leakage/loss joint in B.A.
(i)Connect facemask in demand regulator.
(ii)Open the cylinder valve fully.
(iii)See pressure gage, when it need maximum, close the cylinder valve.
(iv)Check the rate of down of pressure gage – it should be in limit of 10Bar/minute.

3. Low Pressure Test.

(i)Connect facemask in demand regulator.
(ii)Wear facemask.
(iii)Open the cylinder valve fully.
(iv)Close min cylinder valve.
(v)Continue taking breath.

U N Classification
Colour Coding

Class 1- Explosive Orange.

1.1 Explosive with a mass explosion hazard
1.2 Explosive with a projection hazard
1.3 Explosive with predominantly a fire hazard
1.4 Explosive with no significant blast hazard
1.5 very insensitive explosives – blasting agent
1.6 Extremely insensitive explosive articles (detonating)

Class 2 - Gases
2.1 Flammable Gases Red.
2.2 Non-flammable Gases Green.
2.3 Poison/Toxic Gases White.

Class 3 - Flammable Liquid Red.

3.1 Flash point below – 180c (00 F)
3.2 Flash point – 180c & above but less then 230c (730F)
3.3 Flash point of 230c & up to 610c (1410F)

Class 4 - Solids
4.1 Flammable Solids White
4.2 Spontaneously Combustible Material Red
4.3 Materials these are dangerous when wet Blue

Class 5 - Oxidizing Substance Yellow

5.1 Oxidizers
5.2 Organic Peroxides
Class 6 - Poisons & Toxic Materials White
6.1 Poisonous Materials

Class 7 - Radioactive Materials White

Class 8 - Corrosives Black &White

Class 9 - Miscellanies Hazardous Material Not Specified

9.1 Miscellanies Dangerous Goods.
9.2 Environmentally Hazardous Substance.
9.3 Dangerous Substance.

FIRE ALARM SYSTEM

A fire detection & alarm system is a key element among the fire protection features of any
building. Fire alarm system is the result of a series of interlocking interrelated steps –
Specify Manufactures, Install, Maintain, Test, use.

Types of signals
Fire alarm system may provide 3 types of signals – Alarm, Supervisory & Trouble.

An alarm signal is a warning of fire that requires immediate action.

A supervisory signal indicates that action is needed in connection with the operation of other
fire protection systems those are monitored by fire-alarm system.

A trouble signal indicates a fault in a monitored circuit or component of fire-alarm system or

the disarrangement of the primary or secondary power supply.

Basics
Fire-alarm systems are classified according to the function. They are expected to perform.
The basic components of each system are –
1. A system Control unit.
2. A primary or main power supply.
3. A secondary or stand – by power supply.
4. one or more initiating device circuit or signalling line circuit.
5. One or more fire alarm notification appliance circuit.
6. Many system also have an off – premises connection by means of an auxiliary fire alarm
system.

Circuit
Fire alarm system have 3 basic types of circuit
1. Initiating Device Circuit (IDC).
2. Notification Appliance Circuit (NAC).
3. Signalling Line Circuit (SLC).
Many fire-alarm system control units have more than one initiating device circuit so that
the fire location can be indicated on an enunciator panel by floor, wing, subsection, or room.
The enunciator can be built into the control unit or located in a lobby,
maintenance area, telephone switchboard room or some other location easily accessible to
fire service personnel.
 DETERMINING FIRE HAZARDS
This section consists of two steps: first, identifying the existing fire hazards in the workplace
and, second, taking action to resolve them. The inspection checklist, in Appendix A,
provides a guide for precise fire-safe practices that must be followed. The location of these
major fire hazards are denoted in Appendix C. Also included in Appendix C is a listing of
the personnel responsible for the maintenance of the equipment and systems installed to
prevent or control fires.

Material hazards shall be identified, as evident on the specific Material Safety Data Sheets
(MSDS), and label on containers as soon as they arrive in the workplace. The
identification system shall also include incorporation into the company’s hazard
communication program.

OXYGEN-ENERGIZED ATMOSPHERES
Oxygen-enriched atmospheres involve operating rooms and anesthesia machines, oxygen
tents as used by ambulances, fire and police or rescue squads; hospitals and laboratory
supply systems; cutting and welding. If practical, non-flammable anesthetic agents will be
used. To prevent dangerous adiabatic heating of flammable anesthetic gases, the cylinder
valves will be opened very slowly to allow the gradual introduction of the high pressure gas
downstream from the cylinder valve. This will permit a slow build up of pressure and hence
temperature. An aid to the identification of hazards associated with medical agents and gases
in NFPA 704, Standard Systems for the Identification of the Fire Hazards of Materials.

INDUSTRIAL TRUCKS
The type of industrial truck being used shall be approved for use within any building storing
hazardous materials. All re-fueling operations shall be conducted outside and away from
storage of flammable materials. Areas that are used for maintenance and battery charging of
electrical trucks should be separated from storage areas.

STORAGE AND HANDLING PROCEDURES

The storage of material shall be arranged such that adequate clearance is maintained away
from heating surfaces, air ducts, heaters, flue pipes, and lighting fixtures. All storage
containers or areas shall prominently display signs to identify the material stored within.
Storages of chemicals shall be separated from other materials is storage , from handling
operations, and from incompatible materials. All individuals containers shall be identified as
to their contents. Only containers designed, constructed, and tested in accordance with the
U.S Department of Transportations specifications and regulations are used for storage of
compressed or liquified gases. Compressed gas storage rooms will be areas reserved
exclusively for that purpose with good ventilations and at least 1 hour fire resistance rating.
The gas cylinder shall be secured in place and stored away from any heat or ignition source.
Pressurized gas cylinder shall never be used without pressure regulators.

ORDINARY COMBUSTIBLE
• Wooden pallets will not be stacked over 6 feet tall. If feasible, extra pallets will be stored
outside or in separate buildings to reduce the risk of fire hazards.
• Piles of combustible materials shall be stored away from buildings and located apart from
each other sufficiently to allow firefighting efforts to control an existing fire.
FLAMMABLE MATERIALS
• Bulk quantities of flammable liquids shall be stored outdoors and away from buildings.
Smaller quantities are subsequently brought into a mixing room where they are prepared for
use. The mixing room shall be located next to an outside wall equipped with explosion relief
vents. The room shall also have sufficient mechanical ventilation to prevent the accumulation
of flammable vapor concentration in the explosive range.
• Small quantities (limited to amount necessary to perform an operation for one working
shift)
of flammable liquids shall be stored in, and also dispensed from, approved safety containers
equipped with vapor-tight, self-closing caps, screens or covers.
• Flammable liquids shall be stored away from sources that can produce sparks.
• Flammable liquids shall only be used in areas having adequate and, if feasible, positive
ventilation. If the liquid is highly hazardous, the liquid shall only be used in areas with a
local exhaust ventilation.
• Flammable liquids shall never be transferred from one container to another by applying air
pressure to the original container. Pressurizing such containers may cause them to rupture,
creating a serious flammable liquid spill.
• When dangerous liquids are being handled, a warning sign will be posted near the
operation, notifying other employees and giving warning that open flames are hazardous and
are to be kept away.
• The storage and usage areas will include fire-resistive separations, automatic sprinklers,
special ventilation, explosion-relief valves, separation of incompatible materials, and the
separation of flammable materials from other materials.

HOUSEKEEPING PREVENTIVE TECHNIQUES

The following are housekeeping techniques and procedures to prevent occurrences of fire.
• Keep storage and working areas free of trash.
• Place oily rags in covered containers and dispose of daily.
• Do not use gasoline or other flammable solvent or finish to clean floors.
• Use non-combustible oil-absorptive materials for sweeping floors.
• Dispose of materials in non-combustible containers that are emptied daily.
• Remove accumulation of combustible dust.
• Don’t refuel gasoline-powered equipment in a confined space, especially in the presence of
equipment such as furnaces or water heaters.
• Don’t refuel gasoline-powered equipment while it is hot.
• Follow proper storage and handling procedures.
• Ensure combustible materials are present only in areas in quantities required for the work
operation.
• Clean up any spill of flammable liquids immediately.
• Ensure that if a worker’s clothing becomes contaminated with flammable liquids, these
individuals change their clothing before continuing to work.
• Post “No Smoking” caution signs near the storage areas.
• Report any hazardous condition, such as old wiring, worn insulation and broken electrical
equipment, to the supervisor.
• Keep motors clean and in good working order.
• Don’t overload electrical outlets.
• Ensure all equipment is turned off at the end of the work day.
• Maintain the right type of fire extinguisher available for use.
• Use the safest cleaning solvents (non-flammable and nontoxic) when cleaning electrical
equipment.
• Ensure that all passageways and fire doors are unobstructed. Stairwell doors shall never be
propped open, and materials shall not be stored in stairwells.
• Periodically remove over spray residue from walls, floors, and ceilings of spray booths and
ventilation ducts.
• Remove contaminated spray booth filters from the building as soon as replaced, or keep
immersed in water until disposed.
• Don’t allow material to block automatic sprinkler systems, or to be piled around fire
extinguisher locations. To obtain the proper distribution of water, a minimum of 18 inches of
clear space must
be maintained below sprinkler deflectors. If there are no sprinklers, a 3 foot clearance
between piled material and the ceiling must be maintained to permit use of hose streams.
These distances must be doubled when stock is piled higher than 15 feet.
• Check daily for any discard lumber, broken pallets or pieces of material stored on site and
remove properly.
• Replies immediately any pile of material which falls into an aisle or clear space.
• Use weed killers that are not toxic and do not pose a fire hazard.

FIRE PROTECTION EQUIPMENT

Every building will be equipped with an electrically managed, manually operated fire alarm
system. When activated, the system will sound alarms that can be heard above the ambient
noise levels throughout the workplace. The fire alarm will also be automatically transmitted
to the fire department. Any fire suppression or fire detection system will automatically
actuate the building alarm system.

The automatic sprinkler system, if applicable, will adhere to NFPA 13, Standard for the
Installation of Sprinkler Systems. The sprinkler system and components will be electrically
supervised to ensure reliable operation. This includes gate valve tamper switches with a local
alarm at a constantly attended site when the valve is closed. If a single water supply is
provided be a connection to the city mains, a low pressure monitor is included. If pressure
tanks are the primary source of water, air pressure, water level, and temperature shall be
supervised. If fire pumps are provided to boost system pressure, supervision will monitor
loss of pump power, pump running indication, low system pressure, and low pump suction
pressure.
In hospitals, every patient sleeping room will be provided with an outside window or door
that can be opened from the inside; this will allow venting of products of combustion if there
is a fire. A specially designed smoke control system can be a substitute for an outside
window.
Portable fire extinguishers are placed in a building. Fire extinguishers must be kept fully
charged and in their designated places. The extinguishers will not be obstructed or obscured
from view. A map indicating the locations of all fire extinguishers for this company is
located in Appendix E. The fire extinguishers will also be inspected at least monthly, to
make sure that they are in their designated places, have not been tampered with or actuated,
and are not corroded or otherwise impaired. Attached inspection tags shall be initialed /dated
each month.
The location of all hydrants, hose houses, portable fire extinguishers, or other fire protective
equipment should be properly marked with arrows and signs painted on the pavement.

TRAINING
All employees shall be instructed on the locations and proper use of fire extinguishers in
their work areas. Employees shall also be instructed as to how to operate the building’s fire
alarm system, and be familiar with evacuation routes. The training of all employees shall
include the locations and types of materials and/or processes which pose potential fire
hazards. The training program shall also emphasize the following:
1. Use and disposal of smoking materials
2. The importance of electrical safety
3. Proper use of electrical appliances and equipment
4. Unplugging heat-producing equipment and appliances at the end of each work day
5. Correct storage of combustible and flammable materials
6. Safe handling of compressed gases and flammable liquids (where appropriate) Ongoing
training shall include regularly scheduled fire drills. Training documentation shall be place in
Appendix D.

CHECKLIST FOR FIRE PREVENTION

The checklist should be reviewed regularly and kept up-to-date.

ELECTRICAL EQUIMENT
_ No makeshift wiring.
_ Fuse and control boxes clean and closed.
_ Extension cords serviceable.
_ Circuits properly fused or otherwise protected.
_ Motors and tools free of dirt and grease.
_ Equipment approved for use in hazardous areas (if required).
_ Lights clear of combustible materials.
_ Safest cleaning solvents used.

FRICTION
_ Machinery properly lubricated.
_ Machinery properly adjusted and/or aligned.
SPECIAL FIRE-HAZARD MATERIALS
_ Storage of special flammable isolated.
_ Non-metal stock free of tramp metal.

WELDING AND CUTTING

_ Area surveyed for fire safety.
_ Combustible removed or covered.
_ Permit issued.

OPEN FLAMES
_ Kept away from spray rooms and booths.
_ Portable torches clear of flammable surfaces.
_ No gas leaks.

PORTABLE HEATERS
_ set up with ample horizontal and overhead clearances.
_ safely mounted on non-combustible surfaces.
_ Secured against tipping or upset.
_ Use of steel drums prohibited.
_ Combustibles removed or covered.
_ Not used as rubbish burners.
HOT SURFACES
_ hot pipes clear of combustible materials.
_ Soldering irons kept off combustible surfaces.
_ ample containers available and serviceable.
_ Ashes in metal containers.

SMOKING AND MATCHES

_ “No smoking” and “smoking” areas clearly marked.
_ No discarded smoking materials in prohibited areas.
_ Butt containers available and serviceable.

SPONTANEOUS IGNITION
_ Flammable waste material in closed, metal containers.
_ piled material, dry, and well ventilated.
_ Flammable waste material containers emptied frequently.
_ Trash receptacle emptied daily.

STATIC ELECTRICITY
_ Flammable liquid dispensing vessels grounded and bonded.
_ Proper humidity maintained.
_ Moving machinery grounded.

HOUSEKEEPING
_ No accumulation of rubbish.
_ Premises free of unnecessary combustible materials.
_ Safe storage of flammables.
_ No leaks or dripping of flammables and floor free of spills.
_ Passageways clear of obstacles.
_ Fire doors unblocked and operating freely.
_ Automatic sprinklers unobstructed.

FIRE PROTECTION
_ Proper type of fire extinguisher.
_ extinguishing system in working order.
_ Fire extinguisher in proper location.
_ Service date current.
_ Access to fire extinguishers unobstructed.
_ Personnel trained in use of equipment.
_ Access to fire extinguishers clearly marked.
_ Personnel exits unobstructed and maintained.
_ Fire protection equipment turned on.

ON-SITE EMERGENCY PLAN

The plan should include the following information. However, necessary addition and
alteration may be made according to the specific type of hazard, and control measure
required.
(1) The purpose of plan:-
- To identify, assess, fore see and work out the possible hazard.
- To work out a plan with detailed instruction to cope with the emergent situation arising out
of the hazard.
- The plan should be declared to cope up with any emergency which may arise due to own
operations, adjacent operation and outside forces at any time of day and night.
- Adequate emergency control procedures are to be laid down.
- Provision for alarm and emergency equipment must be made.

(2) SITE PLAN of the factory and surrounding:-

The site plan should show the areas of various hazards such as fire, explosion, toxic
release etc. and location of assembly points, fire station, emergency control room, alternate
emergency control room, first-aid or ambulance room, main gate, emergency gate, normal
wide direction, north direction, outside fire station, police station, hospital, communication
facilities and other services – mention their distance also.

(3) TYPE OF OVER ALL EMERGENCIES

All possible types of emergency and how it can occur are to be described. Fire (small
or big) explosion, toxic release, storm, flood etc. are to be described with reasons. Source of
hazards from outside should also be maintained. Effect of prevailing wind and population
density should also be considered.

(4) ASSESSMENT OF IN – PLANT HAZARD

A: Storage hazards and controls:
Name, quantity, type of hazards, control measure, contacts person/address etc.
B: Process hazards and control: Name of process, operation, process parameters, type of
hazard, control measure, contact person & address.
C: Other hazard and control: Name, reason, type, place, control measure, contact person
& address.
D: Inspection, maintenance and monitoring: Name of PPE, scrubbers, safety devices,
location, period of inspection, person I/C, & address, last date of inspection.
E: Preparation of material safety data sheets, of all hazardous chemical used in the
factory.

F: EMERGENCY ORGANIZATION & FUNCTION :

Organization set up is to be constituted and duties of key person are to be prescribed, such
key person are:-

(1) Alarm raiser (2) incident controller (3) Main controller (4) Emergency team
including engineers and experts (5) Fire fighting team (6) Gas control team (7) First –
aid and health care team (8) Ambulance & evacuation team (9) safety officer (10)
Security officer.
Names, designation, telephone number of above persons are to be displayed on main
notice board. Their function at time of emergency are to be laid down.

G: EMERGENCY SHUT DOWN PROCEDURE

Detailed instruction on emergency shutdown of the plant is to be laid down.
Provision for emergency source of power, water reservoir is to be made in the
plant.

H: LINK WITHOFF-SITE EMERGENCY PLAN

To deal with the emergency hazard extending outside the factory premises and effecting
neighbouring area, off site emergency control procedure and public warning procedure
should be laid down followed.