MODULE 5

Water Based Fire Extinguisher

• Water is the primary liquid used in these extinguishers, although sometimes other additives are also included.
• A drawback for pure water fire extinguishers is that it is not suitable for use in freezing conditions since the
water inside will freeze and render the extinguisher unusable. Certain types of water fire extinguishers contain
antifreeze which will allow the extinguisher to be used in freezing conditions.
• Water type fire extinguishers can also sometimes contain wetting agents which are designed to help increase
its effectiveness against fire.
• These extinguishers are intended primarily for use on Class A fires.
• Water mist extinguishers are a type of water fire extinguisher that uses distilled water and discharges it as a
fine spray instead of a solid stream. Water mist extinguishers are used where contaminants in unregulated
water sources can cause excessive damage to personnel or equipment.
• Typical applications include operating rooms, museums, and book collections.

Carbon Dioxide type

Fire Extinguisher
• The principal advantage of Carbon Dioxide (CO2) fire extinguishers is that the agent does not leave a residue
after use.
• This can be a significant factor where protection is needed for delicate and costly electronic equipment.
• Other typical applications are food preparation areas, laboratories, and printing or duplicating areas.
• Carbon dioxide extinguishers are listed for use on Class B and Class C fires.
• This type of fire extinguisher is not recommended for outdoor use where windy conditions prevail or for
indoor use in locations that are subject to strong air currents, because the agent can rapidly dissipate and
prevent extinguishment.
• The concentration needed for fire extinguishment reduces the amount of oxygen in the vicinity of the fire and
should be used with caution when discharged in confined spaces.
 DOW Fire & Explosion Index

Summary

 Originated due to poor loss (accident)

record in 1966
 One of the first “chemical plant” hazard
analysis systems
 Unique Features
– Maximum Probable Property Damage
– Maximum Probable Days Outage
 Continues to be upgraded in use and
application
 Fill out like a “Tax Form”

DOW Fire & Explosion Index

DOW Fire & Explosion Index

F & EI
The expected damage of
QUANTIFY
 Uses material factors that relate to reactivity potential fire &
and flammability explosion incidents in
realistic terms
 Identifies equipment that can present a
flammable or explosive hazard Equipment that would
IDENTIFY likely contribute to the
 Suggests approaches to control a hazard
creation or escalation
 Useful in determining plant layout and of an incident
separation between vessels
 Requires engineering judgement The fire & explosion
COMMUNICATE potential to design
 Is not a perfect tool teams and plant
personnel
 Is a useful tool
DOW Fire & Explosion Index DOW Fire & Explosion Index

 Material Factor LOSS CONTROL CREDITS

– Measure of Reactivity and
Flammability Are features that have proved
 General Process Hazards beneficial in preventing
– Play a primary role in serious incidents and
determining the magnitude of reducing the magnitude of a
a loss incident particular incident
 Special Process Hazards
– Contribute to the probability of * Process Control
a loss incident
* Material Isolation
 Fire & Explosion Index
* Fire Protection
– A measure of the relative
hazard and relates to an
exposure radius

DOW Fire & Explosion Index

Actual Maximum Probable Property

Damage
Represents the property damage that
could result from an incident of
reasonable magnitude with adequate
functioning of protective equipment

Maximum Probable Days Outage

Time required to rebuild the plant to
its original capacity

Business Interruption
The lost profit to the company due to
an incident
 DOW Fire & Explosion Index DOW Fire & Explosion Index
IDENTIFY PERTINENT PROCESS UNIT

(An item of equipment that could impact the process

Items Required to Develop an F & EI from a safety & loss prevention standpoint)

1. Accurate Plot Plan for an existing plant

* Chemical Energy Potential (Material
2. Preliminary Plot Plan for a new plant Factor)
3. Process Flow Sheet * Quantity of hazardous materials in
the process unit
4. F & EI Hazard classification guide
* Capital density
5. F & EI form * Process pressure and temperature
* Past history of problems

Not all unit operation need to be analyzed.

Knowledge of the process is essential

DOW Fire & Explosion Index

DOW Fire & Explosion Index
MATERIAL FACTOR

* Measure of the flammability

(NF) and reactivity (NR) of a
material

* Material factor adjusted for

process conditions
- Flash Point
- Boiling Point
DOW Fire & Explosion Index

DOW Fire & Explosion Index DOW Fire & Explosion Index
CONTRIBUTING HAZARD GENERAL PROCESS HAZARDS
FACTORS F1

Evaluate the process unit to

eliminate over estimating Penalties for:
penalties
Exothermic/Endothermic
* General Process Hazards (F1)
Material Handling & Transfer
Enclosed processes
* Special Process Hazards (F2)
Access
Drainage and spill control

F & EI workbook has various penalties

DOW Fire & Explosion Index DOW Fire & Explosion Index
SPECIAL PROCESS HAZARDS
SPECIAL PROCESS HAZARDS
F2 F2
Penalties for: Pressure Penalty
Toxic materials (0.2 x NH)
Sub-atmospheric pressure
(P<500mHg, 0.5)
Dust explosions
Operating in flammable range
Low temperature operation
Corrosion & Erosion
Leakage
Rotating equipment

F & EI workbook has various penalties

DOW Fire & Explosion Index DOW Fire & Explosion Index
SPECIAL PROCESS HAZARDS SPECIAL PROCESS HAZARDS
F2 F2
Quantity of Flammable/Unstable Use of fired equipment
material

Curve A-1 Release above flash point or combustible

dust
Separate figures for process, storage and solids Curve A-2 Released above boiling point
 DOW Fire & Explosion Index DOW Fire & Explosion Index

UNIT HAZARD FACTOR (F3)

F & EI USED TO DETERMINE

An area having a potential for impact from a flammable or over pressure

F3 = F 1 X F 2 event

F & EI = Material Factor X F3

DOW Fire & Explosion Index DOW Fire & Explosion Index
Area of Exposure
Degree of
F & EI Hazard Exposure radius from empirical
relationship
1 - 60 Light

61 - 96 Moderate

97 - 127 Intermediate

128* - 158 Heavy

159+ Severe
Determined from spills of flammable materials 3 in.
* Trigger for more detailed PHA deep as well as potential vapor air mixtures
DOW Fire & Explosion Index DOW Fire & Explosion Index
Volume of Exposure Damage Factor

Calculate volume as a cylinder with Determine damage factor from

height equal to radius empirical relationship of Unit
Hazard (F3) and Material Factor
(MF)

Determine replacement value of

equipment in the area (volume)

DOW Fire & Explosion Index DOW Fire & Explosion Index
LOSS CONTROL CREDIT
FACTORS
BASE MAXIMUM PROBABLE
PROPERTY DAMAGE

Base Maximum Probable Property

Damage (Base MPPD)

Value of the area of exposure

X
F & EI workbook has various credits
Damage Factor
DOW Fire & Explosion Index DOW Fire & Explosion Index
ACTUAL MAXIMUM PROBABLE MAXIMUM PROBABLE DAYS
PROPERTY DAMAGE OUTAGE (MPDO)
Maximum Probable Days Outage
Actual Maximum Probable Property (MPDO) determined empirically
Damage (Actual MPPD) from actual MPPD

Base MPPD

Credit Factor

DOW Fire & Explosion Index DOW Fire & Explosion Index
BUSINESS INTERRUPTION RISK ANALYSIS

Business Interruption (BI)

Maximum Probable Days Outage

(MPDO)

{Lost Profit before tax/day

+
Fixed Cost/day}
 DOW Fire & Explosion Index DOW Fire & Explosion Index
WHAT CAN I DO TO LOWER
THE RISK?

* Reduce the Hazards (most impact)

The DOW F & EI system
* Add Loss Control Features (Least
impact) challenges you to

* Increase spacing (plant layout)

determine how much risk
you are willing to accept.
It is more effective to reduce the hazards
early in the project than to add loss
control features late in the project

The system makes us quantify the risk

and suggests ways to reduce the risk

What Is Preliminary Hazard Analysis Characteristics Of PHA

• It relies on brainstorming and expert judgment to assess the significance of hazards and
 Preliminary hazard analysis (PHA) is usually the first attempt in the system safety assign a ranking to each situation.
process to identify and categorize hazards or potential hazards associated with the • It is typically performed by one or two people who are knowledgeable about the type of
operation of a proposed system, process, or procedure; it is used in the early stages of activity in question.

system design. • It is applicable to any activity or system

• It can be used as a high-level analysis early in the life of a process.
 It is a semi-quantitative analysis that is performed to identify all potential hazards and
• It is used to generates qualitative descriptions of the hazards related to a process.
accidental events that may lead to an accident, rank the identified accidental events Provides a qualitative ranking of the hazardous situations; this ranking can be used to
according to their severity and identify required hazard controls and follow-up actions. prioritize recommendations for reducing or eliminating hazards in subsequent phases of
the life cycle.
 Preliminary hazard analysis that can be used under different names, such as Rapid Risk
• Quality of the evaluation depends on the quality and availability of documentation, the
Ranking and Hazard Identification (HAZID).
training of the review team leader with respect to the various analysis techniques
employed, and the experience of the review teams.
 Steps To Carrying Out Preliminary Hazard Analysis
Advantages And Disadvantages Of PHA (PHA)

 Advantages
1. PHA prerequisites: This involves, establishing a PHA team, description of
• Helps ensure that the system is safe
• Modifications are less expensive and easier to implement in the system to be analysed, and collection of risk information from previous
the earlier stages of design system.
• Decreases design time by reducing the number of surprises
 Disadvantages 2. Hazard identification: This is where all hazards and possible accidental

• Hazards must be foreseen by the analysts events must be identified. All part of the system should be considered at
• The effects of interactions between hazards are not easily
recognized this stage. All findings should be recorded.

 Note: No hazards are too insignificant to be recorded.

Hazard & Operability Analysis (HAZOP)

3. Consequence and frequency estimation: To determine the risk level, we have to  Hazard and Operability Analysis (HAZOP) is a structured and systematic
estimate the frequency and the severity of each accidental event. At this stage, the
technique for system examination and risk management.
 In particular, HAZOP is often used as a technique for identifying potential
consequence and frequency of every hazard is considered.
hazards in a system and identifying operability problems likely to lead to
4. Risk ranking and follow-up actions: Risk is established as a combination of a given nonconforming products.
event/consequence and a severity of the same event/consequence. This will enable a  HAZOP is based on a theory that assumes risk events are caused by
ranking of the deviations from design or operating intentions.
events/consequences in a risk matrix. This ranking level will determine the follow up  Identification of such deviations is facilitated by using sets of “guide
words” as a systematic list of deviation perspectives.
actions necessary for the risk.
 This approach is a unique feature of the HAZOP methodology that helps
stimulate the imagination of team members when exploring potential
deviations.
 HAZOP Methodology Definition Phase

 The Definition Phase typically begins with preliminary identification of risk

 The HAZOP analysis assessment team members.
process is executed  HAZOP is intended to be a cross-functional team effort, and relies on
in four phases as specialists (SMEs) from various disciplines with appropriate skills and
illustrated below: experience who display intuition and good judgment.
 SMEs should be carefully chosen to include those with a broad and
current knowledge of system deviations.
 HAZOP should always be carried out in a climate of positive thinking and
frank discussion.
 During the Definition Phase, the risk assessment team must identify the
assessment scope carefully in order to focus effort.
 This includes defining study boundaries and key interfaces as well as key
assumptions that the assessment will be performed under

Preparation Phase

 The Preparation Phase typically includes the following activities:  Risk assessment teams are responsible for identifying the guide words
Identifying and locating supporting data and information that will best suit the scope and problem statement for their analysis.
 Identification of the audience and users of the study outputs Some common HAZOP guide words include:
 Project management preparations (ex: scheduling meetings,
transcribing proceedings, etc.)
 Consensus on template format for recording study outputs
 Consensus on HAZOP guide words to be used during the study
 Examination Phase

 The HAZOP guide words are then applied to each of the elements.
 The Examination Phase begins with identification of all elements (parts or
 In this fashion a thorough search for deviations is carried out in a
systematic manner.
steps) of the system or process to be examined. For example:
 It must be noted that not all combinations of guide words and elements
are expected to yield sensible or credible deviation possibilities.
 Physical systems may be broken down into smaller parts as necessary
 As a general rule, all reasonable use and misuse conditions which are
expected by the user should be identified and subsequently challenged to
 Processes may be broken down into discrete steps or phases
determine if they are “credible” and whether they should be assessed
any further.
 Similar parts or steps may be grouped together to facilitate assessment
 There is no need to explicitly document the instances when combinations
of elements and guide words do not yield any credible deviations

Documentation & Follow-up Phase Risk Review

 The documentation of HAZOP analyses is often facilitated by utilizing a  On a long-term basis, operational feedback should confirm that the
template recording form as detailed in IEC Standard 61882.
 Risk assessment teams may modify the template as necessary based on
assessment and control steps are adequately addressing the risk
factors such as: question.
 Regulatory requirements
 It is also important to note that new risks may arise from risk control
 Need for more explicit risk rating or prioritization (ex: rating deviation
probabilities, severities, and/or detection) practices.
 Company documentation policies
 Sometimes risks that were not originally identified or may have been
 Needs for traceability or audit readiness
filtered out during the initial risk assessment can become aggravating
 Other factors
factors due to the implementation of risk control measures.
 Risk Communication

 HAZOP is a powerful communication tool.

 The output of the tool should always be presented at a level of detail

appropriate for the various stakeholders.

 This is important not just for presenting results, but also for obtaining

early buy-in on the approach.

 das

 asd

das Controlling Chemical Hazards

 Controlling exposures to chemical hazards and toxic substances is the fundamental method of protecting
 asd workers.
 A hierarchy of controls is used as a means of determining how to implement feasible and effective
controls.
 Engineering and work practice controls must be the primary means used to reduce employee exposure
to toxic chemicals, as far as feasible, and that respiratory protection is required to be used when
engineering or work practice controls are infeasible or while they are being implemented.
 Where possible, elimination or substitution is the most desirable followed by engineering controls.
 Administrative or work practice controls may be appropriate in some cases where engineering controls
cannot be implemented or when different procedures are needed after implementation of the new
engineering controls.
 Personal protection equipment is the least desirable but may still be effective.
 Hazardous Properties of Chemicals

Sometimes they can explode and cause burns, vomiting, drowsiness, etc