Handling Ignitable Liquid

HANDLING IGNITABLE LIQUID
MOH FAHMI NAJAHI

PART 1 :
• Understanding the Hazard of Ignitable Liquid
PART 2 :
• Reducing Ignitable liquid hazard
TRAINING OBJECTIVE
Articulate the unique hazards

associated with ignitable liquid
Describe how to mitigate the
ignitable liquid hazard
List the key challenge
associates with each of the
following and the protection
measures needed to control
them :
Storage
Dispensing
Handling
Processes
Locate the information and
recourses provided to help
understanding how to handle
ignitable liquid.
Understanding the Hazard of Ignitable Liquid
Defining Ignitable Liquid
Understanding the Hazard of Ignitable Liquid
Defining Ignitable Liquid
Objective:
Distinguish the
definition of ‘ignitable’ as
it related to liquid from
other accepted definition
Identify the different
classification schemes of
ignitable liquid
Recognize the standard
symbol used to identify
ignitable liquid
UNDERSTANDING THE HAZARD OF IGNITABLE LIQUID
DEFINING IGNITABLE LIQUID
Combustion
An act or instance of burning; an unusually rapid chemical process (e.g. oxidation)
that produces heat and usually light.
Combustible
Capable of combustion
Flammable
Capable of being easily ignited and of burning quickly
Inflammable
Easily inflamed
Ignitable
Capable of being ignite
Ignitable liquid
Any liquid that burns (it has a measurable fire point, which is the temperature the
vapors ignite and keep burning
NFPA Hazard Identification

symbol
NFPA Hazard Identification symbol and examples

THE SCIENCE OF HAZARD
Objective:
Pinpoint the different
characteristics of ignitable
liquid that influence the
hazard
Recognize the three main
type of liquid release and
ensuring fire scenario
Identify factors that
contribute to ignitable liquid
fire behavior
Define typical use of
ignitable liquid and the
nature of the hazard
Ignitable liquid terminology
Flash point
Boiling point
Specific Gravity
Miscibility
Explosive range
Vapor density
Auto ignition temperature
Spontaneous Ignition
Heat of combustion
Heat release rate




Ignitable liquid
terminology





Fire behavior
Why is Ignitable liquid so hazardous?
Fire behavior
Fire behavior
Fire behavior
Why is Ignitable liquid so
hazardous?
Fire behavior
Why is Ignitable liquid so
hazardous?
Fire behavior
Release/Fire Scenario
Common Failure Mode
Piping left disconnected
Fitting cracking
Flange gasket failure
Coupling separation
Braided metal hose wearing
through
Mechanical damage to any of
the above
Improper connection
involving any of the above
Storage toppling over
Container breached by
material handling equipment
Type of fires formed by ignitable liquid
Spray Fire
Continuous flow of ignitable liquid
under pressure
Liquid is forced through a relatively
small opening
Liquid will mist or atomize
Easy to ignite
Burns instantly like a torch
Limits the fire by stopping the flow of
ignitable liquid
Pool Fire
Ignitable liquid forms pool on floor
Rate of fire spread across pool
varies from seconds t minutes
depending on flash point
Heat release rate is proportional to
pool area
Limit size of pool fire by curbs and
drains or amount of liquid released
High flash point liquid pol fire may
be extinguished if the quantity of
water discharged from sprinkler is
sufficient
Pool Fire
3D-Spill Fire
Pool fire that begins on elevated
level of structure
Burning liquid spills over edge
Create lower level pool fire
Pillars of fire appears
Severe damage occurs
Water will not extinguish
Eliminate pressure or shut off flow
of liquid
Typical uses and nature of hazard











THE SEVEN STEPS OF HAZARD MITIGATION
Objective:
Describe how to reduce the
hazards
Describe how to isolate the
hazard
Define and prevent ignition
source
Describe how to actively protect
against hazard
Identify pr0per ventilation and
exhaust measures
Safeguard your equipment and
processes
Describe the role of Human
element
Three objective of hazard evaluation

Don’t let the fire start
Limit the amount of ignitable liquid that
can find the fire
Limit the extent of damage the ignitable
liquid fire can cause
Seven Steps Process

Three objective of Hazard Evaluation

Each of the seven steps shall be based on three fundamental principles
Step 1 : Reducing the hazard
Relocate:
Outdoor storage relocate
ignitable liquid away from
buildings
A detached building will
conveniently store ignitable liquid
away from the main plant
Relocate ignitable liquid to a
trailer allows for storage away
from buildings
A properly designed storage
area on an exterior wall will
mitigate hazard
Limit Quantities:
The quantity of ignitable liquid should be
kept to a minimum and stored is a
practical way in manufacturing area. The
following container quantity choices are
ranked from the best to worst practices:
An FM approved cabinet storing small
containers safely
Pumping system with appropriate
interlocks that eliminate the needs for
container all together
Use of 5 gal (20L) metal pails
Use of 55 gal (200L) metal drums
Use of 300 gal (1200L) or larger metal
totes
Use of 300 gal (1200L) or larger plastic
intermediate bulk containers
Substitute Less Ignitable Material:

Substitute using FM approved
industrial fluids for hydraulic oil
Replace a highly ignitable solvent such
as acetone with a less ignitable solvent
for cleaning purposes
Replace an ignitable ink with a water
based ink when printing
Replace ignitable paint with water
based paint.
Step 2 : Isolation
Location
Construction
Drainage
Containment
Handling safeguards
Explosion consideration
Step 2 : Isolation
Location
Large Quantities
Very large quantities should be
isolated from the facility by a
good distance to aid in
firefighting efforts and to reduce
fire spread.
Intermediate bulk containers
(IBCs) should be treated
similarly
Step 2 : Isolation
Location
Ignitable Liquid room
While not as good as a low-value
detached building, larger
quantities can be stored in a
dedicated and properly designed
storage room
Step 2 : Isolation
Location
Basement
Ignitable liquid has heavier than
air vapor should never be stored
in basements
Step 2 : Isolation
Location
Aerosols
An FM approved cabinet, special
storage room or a cage area
isolated and contains exploding
and rapidly burning aerosols
Step 2 : Isolation
Location
FM approved cabinets
Store small quantities of liquid in
approved insulated cabinets.
Step 2 : Isolation
Location
Outdoor storage area
Store ignitable liquid in outdoor
areas, provided that they are a
safe distance from the facility.
Take precaution to protect the
area from unauthorized
personnel and potential
vehicular accidents.
Step 2 : Isolation
Location
Low value detached building
Store large quantities of liquid in
a dedicated storage room or a
low value detached building
Step 2 : Isolation
Construction
If ignitable liquid storage or
manufacturing area must be
connected to a larger building,
the non combustible attached
building should share a fire
resistant wall
Vessel and support structure

must be designed to withstand
damage and prevent product
release in the event of accident.
Fire protection of steel support
will prevent overheating
Step 2 : Isolation
Explosion Consideration
Low flash point heated ignitable liquid
may can create explosion hazard that
requires additional design consideration.
When a building is detached from
the main facility, the building should
be designed with pressure relieving
walls, so that that damage to the
structure and equipment is minimized.
Any walls of a storage room
adjoining a main facility should be
pressure resistant, and exterior walls
should be pressure relieving
Where equipment has a severe
explosion potential, the best practice
is isolation.
Step 2 : Isolation
Drainage
Ignitable liquid and sprinkler
discharge is removed
Burning fuel can spread
without drainage
Liquid tight and pitched floors
direct the flow of released liquid
Liquid is discharge to
separator tank or outside
holding basin
Step 2 : Isolation
Containment
Appropriate and durable
closed containers withstand
shipping and handling
FM Approved safety cans

contain the liquid and have flame
arrestors reducing the likelihood
of ignition
Step 2 : Isolation
Containment
Automatic closing or self
closing covers will smother a fire
Enclosed process equipment

and closed pipe systems are
desirable to avoid exposure to
air
Step 2 : Isolation
Containment
Automatic and remote manual
shutoffs interrupt liquid flow in
the event of fire
Fusible link automatic shutoff

valves close when exposed to
fire (applicable for tank outlets of
gravity fed piping)
Step 2 : Isolation
Containment
Curbing or ramping (also
called bunding) contains spills
Spill basins contain the

product and water/foam used to
subdue the fire
Step 2 : Isolation
Containment
Pumping interlocks activated
by fire or leak detector
equipment shut off the pump in a
fire situated to stop feeding the
fire(e.g diesel fuel to an
emergency generator, paint to a
spray booth or hydraulic oil to a
press).
Emergency dump valves open

to remove large quantities of
ignitable liquid from the fire area
to a safe place, such as an
overflow/emergency drain tank
Step 2 : Isolation
Handling safeguard
Step 2 : Isolation
Handling safeguard
Step 3 : Ignition Source Control
Electric equipment
The amount of energy produced in
standard piece of electrical
equipment is more than sufficient to
ignite vapor to a low flash point
ignitable liquid
Use electric equipment that has
been designed and classified for the
specific ignitable liquid environment
Properly maintain the electrical
equipment
Grounding (Earthing) and Bonding

Static electricity arcs when objects
of different potential electrical (e.g.,
caused by flowing liquid) come close
together. A single spark of static
electricity can ignite ignitable vapor.
Hazardous charges cannot built up
on properly grounded conductors
(e.g., metal drums or safety cans)
Bonding is achieved by providing an
electrical connection between the
earth ground, metal drum and safety
can so that they remain at the same
electrical potential.
The same principles are applied to
rotating equipment, such as printing
press with static eliminators.
Controlling Hot Work

Hot work should be avoided in any
area with ignitable liquid present
When repairs requiring hot works
are unavoidable, eliminate all
ignitable liquid and flammable vapor
throughout the area.
Controlling smoking
Smoking is a hazard in any
combustible environment, however
it should be strictly forbidden where
ignitable liquid is stored or presents.
Safe process arrangement

Look at the ignitable liquid
involved in a process and identify
what can cause a fire to start and
the hazard involved that could make
the fire worse.
Step 3 : Ignition Source Control – Safe process arrangement

Actual condition at Kino – Solvent Distillation
- Fact
- Distillation using steam heated rechet to boiling point +/- 80C
- No temperature control/ indicator at the heating vessel
- Cooled destilled temperature using chilled water
- Possible fault condition
- Unbalance flow, solvent, heating and cooling too much solvent vapor, less water
cooling solven vapour excess released to the distillation room.
- Uncontrolled heating, uncontrolled steam flow cooling does not sufficient to
destillate at the design flow solvent vapor released at the destillation room.
- Loss of cooling chilled water off, abnormal (no temperature indicator) no
destillation solvent vapour release to the destillation room
- Ignition source
- Standard lighting fixture
- Static from the operator clothes, etc
- Safeguard
- Mass and heat balance calculation
- Temperature indicator/alarm heating side
- Temperature indicator/alarm cooling side
- Proper operatoe PPE
- Earting pole for operator before entering room
- Classified electrical installation

Safe process arrangement
Example
Quench oil tanks are used for heat-
treating hot metal parts. When the
high flash point quench oil is kept well
below the flash point, the hot parts
can be safely submerged.
If an upset result in the hot parts
being only partially submerged, the oil
is ignited at the surface and develops
into a damaging pool fire.
High oil temperature interlocks and
any design measures that prevent the
‘partial submergence’ scenario,
backed up by appropriate fire
protection for the quench oil surface,
contribute to a safe process
arrangement.
Step 4 : Fire Protection
Automatic Sprinkler
Automatic sprinkler protection
should be provided wherever
ignitable liquid is stored, used or
handled
Sprinklers prevent the intense
heat liberated by ignitable liquid
fires from damaging and
potentially collapsing the building
structure
Sprinklers work in conjunction
with curbs and drains to flush the
ignitable liquid from the fire area
Sprinkler with sufficient
discharge depending on roof
height can actually extinguish
high flash point liquid pool fire
Water Spray
Water spray is used to limit the
heat exposure created by potential
ignitable liquid fires (e.g., water
spray protection of large
transformer actually prevents
damage to adjacent transformers)
These systems are commonly
used for ignitable liquid processes
where a large fire occurs rapidly,
requiring delivery of large amount
of water to a specific area to
achieve sufficient cooling.
Water spray can be used to
protect tank and vessel support in
rooms without a room explosion
hazard.
Special protection systems

For certain severe hazards, special
fixed protection system may be
needed in addition to sprinklers to
protect a specific area or piece of
equipment.
Carbon dioxide (CO2) and various
type of foam and foam water, gaseous
clean agents and wet chemical kitchen
hood protection are examples of
special protection systems.
Special protection systems may be
designed as a local application for a
fixed volume area.
Special protection systems have
many limitation that must be evaluated
or the system sill not work.
Water mist system

Systems are used to protect
enclosure containing high flash
point and limited amount of low
flash point ignitable liquid.
These system are constructed
with attention to the geometry of
the hazard enclosure, which
makes each system fairly unique
and can only be applied as
specifically approved.
Ongoing research is promising
for application to a greater range
of ignitable liquids hazards.
Step 5 : Ventilation and Exhaust
Air Inlets and Natural Draft Ventilation

If make up air is taken from other plant
areas, those areas should be free of ignitable
liquid.
Air inlet preferably should be in exterior
walls and remote from exhaust outlets so that
air will sweep through the hazardous area.
When located in an interior wall, make up air
inlet openings should have automatic closing
fire dampers with a fire rating equal to that of
wall
If gas or oil fired make up heaters are
provided, they should be indirect fired and
properly safeguarded
Natural draft ventilation may be adequate for
unheated class II/III liquid and heated liquid
with a flash point greater than 300F (149C)
Ventilation
Ventilation systems are designed to
keep vapor concentration below the lower
explosive limit (LEL) during normal
operation.
Because flammable vapor is heavier
than air, ventilation intakes are at low
level.
Excessive vapor release caused by
equipment failure, accidental discharge of
heated ignitable liquid or uncontrolled
chemical reaction cannot be adequately
safeguarded by ventilation rates provided
Low level mechanical ventilation must
operate continuously and is typically
designed to provide 1cfm/ft2 (0,3
m3/min/m2) of floor area
Exhaust
Exhaust air should be removed
through a system of blowers, fans and
ductworks terminating pot of doors
away from air inlet, doorways and other
openings.
Exhaust ducts should be constructed
of non combustible material and routed
with a minimum of bends.
The ventilation exhaust system
should tahe suction within 12” (0.3 m)
of the floor.
Step 6 : Safeguarding equipment and processes
Safe startup.
Safe operation.
Safe shut down.
Failsafe interlocks
Step 6 : Safeguarding equipment and processes

Oven Operation, Safe Start-up
Safety control, especially air flow devices, gas pressure switches,
LEL detection equipment and high temperature cutouts should be
proven to be operable and satisfied before start-up can be initiated. No
ignitable liquid should be introduced into the oven until safe condition
exist.
Oven Operation, Safe Operation

Monitoring liquid thickness to ensure that the coating of the product
is consistently applied, airflow switches/sensors and flammable vapor
concentration as a percentage of LEL to ensure condition remain safe,
and burner safely controls to ensure the heat source is stable all
contribute to safe operation. Alarms to warn when conditions are
becoming unsafe and interlocks to initiate a safe shutdown before
hazardous condition is created
Oven Operation, Safe Shut down

Shutdown of the oven should follow prescribed steps that can’t be
bypassed. An orderly sequence in accordance with manufacturer
instruction will ensure ignitable liquid stops entering the oven, burners
are shut off and lingering vapor is purged.
Step 7 : Human Element

Human Error
Hazards
Fire involving ignitable liquid happens fast and
extremely damaging. Knowledgeable people are
vital to avoiding problems. To be effective, human
element efforts must involve cooperation among
top management, line management, all
employees, security personnel and contractors
Trainings
Involve persons must understand the material
processes, safeguard and proper procedures to
avoid damaging and disrupting event.
Step 7 : Human Element

Human Error
Maintenance
Ignitable liquid hazards leave little margin for
error. Failure of a single component can set up
conditions for a fire or explosion. Properly operating
equipment and safeguards, as well as good
housekeeping are critical
Emergency Response
Once an event is initiated, your last chance to limit
the damage depend on effective response.
Paramount to limiting damage are actions to achieve
safe shutdown, stop feeding the fire and ensuring
that available protection is being used effectively to
extinguish the fire and minimize the associate
damage. Consider practice drills. Learn from ‘near
misses’ and adjust plans accordingly
A HAZARD MITIGATION INTERACTIVE REVIEW
Objective:
Use your knowledge of seven
steps of hazard mitigation to
appraise potentially hazardous
scenarios and the effect of
mitigating actions.
Introduction to the interaction

Use the Three fundamental principles
QUESTION??

Handling Ignitable Liquid

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Handling Ignitable Liquid

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HANDLING IGNITABLE LIQUID

MOH FAHMI NAJAHI

Articulate the unique hazards

NFPA Hazard Identification

NFPA Hazard Identification symbol and examples

Ignitable liquid terminology

Ignitable liquid terminology

Ignitable liquid terminology

Ignitable liquid terminology

Ignitable liquid terminology

Ignitable liquid terminology

Ignitable liquid terminology

Ignitable liquid terminology

Ignitable liquid terminology

Ignitable liquid terminology

Typical uses and nature of hazard

Typical uses and nature of hazard

Typical uses and nature of hazard

Typical uses and nature of hazard

Typical uses and nature of hazard

Typical uses and nature of hazard

Typical uses and nature of hazard

Typical uses and nature of hazard

Typical uses and nature of hazard

Typical uses and nature of hazard

Typical uses and nature of hazard

Three objective of hazard evaluation

Seven Steps Process

Three objective of Hazard Evaluation

Step 1 : Reducing the hazard

Step 1 : Reducing the hazard

Step 1 : Reducing the hazard

Substitute Less Ignitable Material:

Vessel and support structure

FM Approved safety cans

Enclosed process equipment

Fusible link automatic shutoff

Spill basins contain the

Emergency dump valves open

Step 3 : Ignition Source Control

Step 3 : Ignition Source Control

Grounding (Earthing) and Bonding

Step 3 : Ignition Source Control

Controlling Hot Work

Step 3 : Ignition Source Control

Step 3 : Ignition Source Control

Safe process arrangement

Step 3 : Ignition Source Control – Safe process arrangement

Step 3 : Ignition Source Control

Step 4 : Fire Protection

Step 4 : Fire Protection

Special protection systems

Step 4 : Fire Protection

Water mist system

Step 5 : Ventilation and Exhaust

Air Inlets and Natural Draft Ventilation

Step 5 : Ventilation and Exhaust

Step 5 : Ventilation and Exhaust

Step 6 : Safeguarding equipment and processes

Safe shut down.

Step 6 : Safeguarding equipment and processes

Oven Operation, Safe Operation

Oven Operation, Safe Shut down

Step 7 : Human Element