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OBJECTIVES
•Summarize basics of industrial safety
OE5092 •Describe fundamentals of maintenance
engineering
INDUSTRIAL SAFETY
•Explain wear and corrosion
Dr. K. Kamalanand •Illustrate fault tracing
•Identify preventive and periodic maintenance

UNIT I INTRODUCTION Terminology


• Accident: That occurrence in a sequence of events that
produces unintended injury, death, or property
• Accident, causes, types, results and control, damage.
– Accident refers to the event, not the result of the event
• mechanical and electrical hazards, types,
• Incident: An unintentional event that may cause
causes and preventive steps/procedure, personal harm or other damage.
• describe salient points of factories act 1948 • Near-miss incident: For purposes of internal reporting,
for health and safety, washrooms, drinking some employers choose to classify as “incidents” the
water layouts, light, cleanliness, fire, guarding, near-miss incident; an injury requiring first aid; the
pressure vessels, etc, Safety color-codes. newly discovered unsafe condition; fires of any size; or
nontrivial incidents of damage to equipment, building,
• Fire prevention and firefighting, equipment property, or product.
and methods. • Unintentional injury: The preferred term for accidental
injury in the public health community. It refers to the
result of an accident.

Accident, causes, types, results and Industrial Accident


control
• According to International Labour Office • An accident (industrial) is a sudden and
statistics, 120 million occupational accidents
occur annually at workplaces worldwide. unexpected occurrence in the industry which
• Of these, 210,000 are fatal accidents. interrupts the orderly progress of the work.
• Every day, more than 500 men or women do not • According to the Factories Act, 1948: “It is an
come home because they were killed by occurrence in an industrial establishment
accidents at work.
• Considering the fact that accidents take a
causing bodily injury to a person who makes
considerable economic toll from nations, him unfit to resume his duties in the next 48
companies and individuals, accidents do not get hours”.
much publicity.

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Industrial Accident
Industrial Injury
• Accident is an unexpected event in the course • An industrial injury is defined as “a personal
of employment which is neither anticipated injury to an employee which has been caused
nor designed to occur. by an accident or an occupational disease and
• An accident is an unplanned and uncontrolled which arises out of or in the course of
event in which an action or reaction of an employment and which could entitle such
object, a substance, a person, or a radiation employee to compensation under Workers’
results in personal injury.
Compensation Act, 1923”.
• It is important to note that self-inflicted
injuries cannot be regarded as accidents.

Types of Accidents
• Accidents may be of different types depending upon the
severity, durability and degree of the injury.
• An accident causing death or permanent or prolonged
disability to the injured employee is called ‘major accident.
• A cut that does not render the employee disabled is termed
as ‘minor’ acci-dent.
• When an employee gets injury with external signs of it, it is
external injury.
• Injury without showing external signs such as a fractured
bone is called an internal one.
• When an injury renders an injured employee disabled for a
short period, say, a day or a week, it is a temporary accident.
• On the contrary, making injured employee disabled for ever is
called permanent accident. Disability caused by accident may
be partial or total, fatal or non-fatal.

• No accident occurs automatically. Instead,


certain factors cause accidents.
• It has been noticed that an accident does not
have a single cause but a multiplicity of
causes, which are often closely related.

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Causes of Accidents Unsafe Conditions (work-related)


• Unsafe working conditions are the biggest cause of acci-dents.
• These are associated with detective plants, tools, equipment’s,
88% of all accidents are caused by unsafe acts machines, and materials.
of people, 10% by unsafe actions and 2% by • Such causes are known as ‘technical causes’.
• They arise when there are improper guarded equipment’s,
“acts of God”. defective equipment’s, faulty layout and location of plant,
inadequate lighting arrangements and ventilation, unsafe storage,
inadequate safety devices, etc.
1. Unsafe Conditions • Besides, the psychological reasons such as working over time,
monotony, fatigue, tiredness, frustration and anxiety are also
2. Unsafe Acts some other causes that cause accidents.

3. Other Causes? • Safety experts identify that there are some high danger zones in
an industry. These are, for example, hand lift trucks, wheel-
barrows, gears and pulleys, saws and hand rails, chisels and screw
drivers, electric drop lights, etc., where about one-third of
industrial accidents occur.

Unsafe Acts Other Causes


• Industrial accidents occur due to certain acts on the part of
workers.
• These acts may be the result of lack of knowledge or skill on the
part of the worker, certain bodily defects and wrong attitude. • These causes arise out of unsafe situational
Examples of these acts are:
and climatic conditions and variations.
• (a) Operating without authority. • These may include excessive noise, very high
• (b) Failure to use safe attire or personal protective equipment’s, temperature, humid conditions, bad working
• (c) Careless throwing of material at the work place.
• (d) Working at unsafe speed, i.e., too fast or too low.
conditions, unhealthy environment, slippery
• (e) Using unsafe equipment, or using equipment’s unsafely. floors, excessive glare, dust and fume,
• (f) Removing safety devices. arrogant behaviour of domineering
• (g) Taking unsafe position under suspended loads. supervisors, etc.
• (h) Distracting, teasing, abusing, quarrelling, day-dreaming,
horseplay
• (i) One’s own accident prone personality and behaviour.

Major accidents in the recent past in


India
• Bhopal, December 1984: In world’s worst chemical disaster, a • Nagothane, November 1990: Explosion at the Indian
methylisocyanate gas leak from the Union Carbide plant in the city Petrochemicals, Nagothane com-plex, 35 persons killed, over
killed over 4000 people. Thousands suffered irreversible health 50 suffered 70 per cent burns.
damage. • Bombay, July 1991: Accident in a Hindustan Organic
• Delhi, December 1985: An petroleum gas leak from the Sriram Chemicals unit near Bombay kills 7 workers.
Foods and Fertilisers Plant in Delhi severely affected workers and • Gwalior, December 1991: Blast at the dyeing department of
those living in the neighbourhood.
GRASIM unit at Gwalior. 14 Killed and 22 severely injured.
• Rourkela, December 1985: Blast furnace accident in Rourkela Steel
Plant. 18 workers affected. • Panipat, August 1992: Ammonia leak at the National
• Durgapur, June 1987: Chlorine leak at Durgapur Chemical Factory Fertilisers Plant, Panipat killed 11, many injured.
created panic all around. Long distance trains were halted. Over • Kahalgaon, October 1992: Boiler explosion in the National
100 were affected. Thermal Power Corporation (NTPC), 11 killed and several
• Bombay, November 1988: Fire at the Bharat Petroleum Refinery at injured.
Mahul, north-east Bombay, killed 32.
• Ramagunaam, September 1989: Major gas leak at Fertilisers
Corporation of India unit at Ramagundam, killed 7.

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Accident Causation Theories


Accidents—Estimated Loss
The domino theory
1. ancestry and social environment
2. worker fault
3. unsafe act together with mechanical and
physical hazard
4. accident
5. damage or injury.

Multiple causation theory


• Multiple causation theory is an outgrowth of the The pure chance theory
domino theory, but it postulates that for a single
accident there may be many contributory factors,
causes and sub-causes, and that certain combinations • According to the pure chance theory, every one
of these give rise to accidents. of any given set of workers has an equal chance
• According to this theory, the contributory factors can of being involved in an accident.
be grouped into the following two categories:
– Behavioural. This category includes factors pertaining to the
• It further implies that there is no single
worker, such as improper attitude, lack of knowledge, lack of discernible pattern of events that leads to an
skills and inadequate physical and mental condition. accident.
– Environmental. This category includes improper guarding of • In this theory, all accidents are treated as
other hazardous work elements and degradation of
equipment through use and unsafe procedures. corresponding to Heinrich’s acts of God, and it is
• The major contribution of this theory is to bring out the held that there exist no interventions to prevent
fact that rarely, if ever, is an accident the result of a them.
single cause or act.

The accident sequence in terms of four Model of accident causation


factors:
1. Error
2. Accident
3. Hazard
4. Injury

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The Frequency Rate Examples


• The Frequency Rate is used to identify the number of
injuries experienced or expected in a period where one
million person-hours of exposure occur.
• The formula to calculate
• The Frequency Rate involves two important pieces of
information:
– firstly, the number of Lost-Time Injuries (LTIs) and,
– secondly, the total hours of exposure experienced by the
group during the period of interest.
• The following formula will produce a Frequency Rate

Average Time Lost Rate (ATLR)

Steps to Prevent Industrial Accidents

1. Proper safety measures


2. Proper selection
3. Safety conscious
4. Enforcement of discipline
5. Incentives
6. Safety committees
7. Proper maintenance of machines, equipment
and infrastructural facilities
8. Safety training.

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What does hazard mean?

Hazard means: Failing to take the necessary precautions can lead to:
• any potential or actual threat to the wellbeing of people, • injury or death
machinery or environment
• fire or property damage

Electrical hazard safety means:


• taking precautions to identify and control electrical hazards

Mechanical and electrical hazards Mechanical Hazards


– Physical hazards include mechanical, electrical, • In general, safety can be increased by ensuring
heat, sound, and radiation hazards. that equipment is well maintained.
– Hazards in each of these categories have the
• Rotating Machinery with rotating parts can
potential to cause injuries (or, in some extreme
cases, even death), but by taking general
catch loose clothing, hands, or hair, potentially
precautions, such as using appropriate protective causing serious injuries.
equipment and emphasizing routine safety, • Uncovered parts may also fly off, thereby
physical hazards can be easily minimized creating additional risk, especially for eye
injuries.

Risk minimization
• Ensure rotating shafts, belts, and pulleys are • Tools
covered by guards, lids, or covers. – Careless use of tools or use of tools in poor
• Check devices attached to a rotor before use condition can cause injuries to the hands, eyes,
head, and limbs.
to ensure that they are tightly fastened.
• Wear eye protection when using uncovered, • Cutting Tools (Scalpels, Razor Blades)
rapidly rotating parts – By design, these instruments are very sharp.
Careless use can quickly result in deep cuts.
• Have a safety shield available.

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Electrical Accidents What are the types of injuries?

Electrical hazards exist in almost every workplace. • Burns


Common causes of electrocution are: • Shocks
• Falls
• making contact with overhead wires
• undertaking maintenance on live equipment
• working with damaged electrical equipment, such
as extension leads, plugs and sockets
• using equipment affected by rain or water ingress KEEP SAFE
KNOW HOW TO CONTROL ELECTRICAL HAZARDS

Electric current
Effect
(contact for 1s)
What are the levels of effect of current? Below 1 mA Not perceptible
1 mA Threshold of feeling, tingling
Slight shock. Not painful. Average individual can let
AC current (mA) Effect on human body 5 mA
go. Involuntary reaction can lead to indirect injuries
1 Slight tingling sensation
6-25 mA
Painful shocks. Loss of muscle control
(women)
2-9 Small shock
Freezing current, "can't let go". The person may be
10-24 Muscles contract causing you to freeze
thrown away from the power source. Individual cannot
25-74 Respiratory muscles can become 9 to 30 mA (men)
let go. Strong involuntary reaction can lead to
paralysed; pain; exit burns often visible
involuntary injuries
75-300 Usually fatal; ventricular fibrillation; entry &
exit wounds visible Extreme pain. Respiratory arrest. Muscles reactions.
50 to 150 mA
Possible Death.
>300 Death almost certain; if survive will have
badly burnt organs and probably require Fibrillation of the heart. Muscular contraction and
1 to 4.3 A
amputations nerve damage occur. Likely death.
10 A Cardiac arrest, severe burns. Death is probable

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Deep burns of skin, muscle and bone How do you respond to electrical incidents?
tissue caused by high voltage
If you come across a person receiving an electric shock:
• if possible, disconnect the electrical supply (switch?)
• assess the situation – never put yourself at risk
• take precautions to protect yourself and anyone else in the vicinity
• apply the first aid principles (e.g. DRSABCD)
• assess the injuries and move the casualty to a safe area if required
• administer first aid if trained
• seek urgent medical attention

What should you do in an electrical emergency? Can you protect yourself from electricity?

For low voltage electricity >50 V AC and 110 V DC • Don’t wear metal objects
• remove the source of electricity supply • Turn power off
• commence CPR if trained • Wear appropriate clothing
• call the emergency number on site • Don’t touch live parts
• Don’t install or repair electrical equipment
For high voltage electricity >1000 V
• Use qualified personnel
• call the emergency number for your site
• Clean and dry leads and plugs before use
• don’t go near the casualty
• Use PPE
• don’t touch the casualty or try to free them with anything

What are other safety measures? Is this a problem?

• Heed warning signs


• Use the right equipment
• Study the operation manual
• Take care of extension leads
• Use only approved extension lamps
• Don’t pull on leads
• Use residual current devices – RCDs
• Use the proper fuses and circuit breakers

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Salient Features of the Factories Act,


COVERAGE OF THE ACT
1948
OBJECTIVES The coverage of the Act is confined to the: -
• The main objective of the Act is to ensure • factories using power and employing 10 or more
adequate safety measures and promote health workers on any working day of the preceding
and welfare of the workers employed in factories twelve months;
as well as to prevent haphazard growth of • factories not using power and employing 20 or
factories. more workers on any working day of the
• The Factories Act is meant to provide protection preceding twelve months; and the
to the workers from being exploited and also • factories specially notified under Section 85 of
provides for improvement of the working the Factories Act by the State Govts./Union
conditions within the factory premises Territories.

IMPORTANT CONCEPTS AND


DEFINITIONS Worker means a person (employed directly or
• Factory means any premises including the precincts through any agency including a contractor) with or
thereof:- without the knowledge of the principal employer,
whether for remuneration or not in any
– i) wherein ten or more workers are working, or were
working on any day of the preceding twelve months and manufacturing process, or in cleaning any part of
in any part of which a manufacturing process is being the machinery or premises used for a
carried on with the aid of power, or is ordinarily so manufacturing process, or in any kind of work
carried on, or incidental to or connected with the manufacturing
– ii)wherein twenty or more workers are working or were process, or the subject of manufacturing process
working on any day of the preceding twelve months, and (but does not include any member of the armed
in any part of which a manufacturing process is being forces of the Union).
carried on without the aid of power, or is ordinarily so
carried on

Manufacturing process means any process for: - Hazardous Process means any process or activity in
i) Making, altering, repairing, ornamenting, finishing, relation to an industry specified in the First
packing, oiling, washing, cleaning, breaking up, Schedule where, unless special care is taken, raw
demolishing or otherwise treating or adapting any
article or substance with a view to its use, sale,
materials used therein or the intermediate or
transport, delivery or disposal or finished products, by- products, wastes or effluents
ii) Pumping oil, water, sewage or any other substance thereof would cause material impairment of the
or health of the persons engaged in or connected
iii) Generating, transforming or transmitting power or therewith, or results in the pollution of the general
iv) Composing types for printing, printing by letter environment, provided that the State Government
press, lithography, photogravure of other similar may, by notification in the Official Gazette, amend
process or book binding, the First Schedule by way of addition, omission or
v) Constructing, reconstructing, repairing, refitting, variation of any industry specified in the said
finishing or breaking up ships or vessels, Schedule.
vi) Preserving or storing any article in cold storage.

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Fatal Injury means injury resulting from industrial Average Daily Number of Workers Employed The
accident which caused death to the worker. average daily number of workers employed is
calculated by dividing the aggregate number of
Non-Fatal Injury means injury resulting from attendances on all the working days (that is,
industrial accident, which prevented injured worker mandays worked) by the number of working days in
from attending to work for a period of 48 hours or the year. Attendance on separate shifts (e.g.
more immediately following the injuries. nightand day shifts) should be counted separately.
Adult means a person who has completed his Days on which the factory was closed for whatever
eighteenth year of age. cause and days on which the manufacturing process
was not carried on should not be treated as working
Adolescent means a person who has completed his days. Partial attendance for less than half a shift on
fifteenth year of age but has not completed his a working day should be ignored, while attendance
eighteenth year. for half a shift or more on such day should be
Child means a person who has not completed his treated as full attendance
fifteenth year of age

Mandays Worked means total number of attendances


during a calendar year.
The Average number of hours worked per week
means the total actual hours worked by all workers
during the year excluding the rest intervals but
including overtime worked divided by the product
of average number of workers employed daily in the
factory and 52 weeks or Average number of hours
worked per week = total number of man hours
worked/number of weeks in which production
process has taken place.* average number of
workers employed daily. In case the factory has not
worked for the whole year, the number of weeks
during which the factory worked should be used in
place of 52

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Lighting
This section states:
• Firstly, There should be proper lighting in all the
places of the factory from where the workers of
the factory pass.
• In every factory, effective provision shall, so far as
is practicable, be made for the prevention of
glare, either directly from a source of light or by
reflection from a smooth or polished surface;
• the formation of shadows to such an extent as to
cause eye-strain or the risk of accident to any
worker.

Drinking Water Washrooms


• This section states that every factory should
• This section states that in every factory, there make arrangements of latrine and urinals for
should be proper arrangements for a sufficient the employees and the rules are laid down by
supply of wholesome drinking water and shall the State Government in this behalf.
be legibly marked as “drinking water”.

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• Red:
Fire protection equipment
Danger, high risk of injury or death
Safety Colour Codes Emergency stops and alarms
• Orange:
Moderate risk of injury
Guarding devices
• The American National Standards Institute has • Yellow:
Caution statements
established rules governing what specific Minor risk of injury
Materials handling equipment
colors mean. • Green:
Safety equipment or information
• Standardized rules can help people easily First aid equipment or location
• Blue:
recognize and understand the message being No immediate hazard
conveyed. • Trucks, rail cards and other containers must have placards attached indicating the
hazard level of the container’s contents.
• The meanings of various colors on these placards also are standardized:
• Red – combustible materials
Yellow – oxidizers
White – poison or toxic
Orange – explosives
Green – nonflammable gas
Red and white stripe – Flammable solid

Match the pictogram to the hazard

Answers

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• Ignition sources can include any material, equipment or


Fire Protection and Prevention operation that emits a spark or flame—including
obvious items, such as torches, as well as less obvious
items, such as static electricity and grinding operations.
• Fire is a chemical reaction that requires three elements to be
present for the reaction to take place and continue. • Equipment or components that radiate heat, such as
• The three elements are: kettles, catalytic converters and mufflers, also can be
– Heat, or an ignition source ignition sources.
– Fuel • Fuel sources include combustible materials, such as
– Oxygen wood, paper, trash and clothing; flammable liquids,
such as gasoline or solvents; and flammable gases, such
• These three elements typically are referred to as the “fire as propane or natural gas.
triangle.” Fire is the result of the reaction between the fuel • Oxygen in the fire triangle comes from the air in the
and oxygen in the air. atmosphere.
• Depending on the type of fuel involved, fires can occur
• If one element of the fire triangle is not present or removed, with much lower volume of oxygen present than
fire will not start or, if already burning, will extinguish. needed to support human respiration.

Fire Classifications Industrial Fire Protection


• Fires are classified as A, B, C, D or K based on the type of
substance that is the fuel for the fire, as follows:
• Class A—fires involving ordinary combustibles, such as paper, Industrial facilities have unique hazards
trash, some plastics, wood and cloth. A rule of thumb is if it Chemical production or use
leaves an ash behind, it is a Class A fire. Storage of flammable or volatile materials
Access controls or personnel restrictions
• Class B—fires involving flammable gases or liquids, such as
propane, oil and gasoline Unique operations require additional considerations included with
simpler methods
• Class C—fires involving energized electrical components
• Class D—fires involving metal. A rule of thumb is if the name Additional considerations require the use of an engineering
of the metal ends with the letters “um,” it is a Class D fire.
Examples of this are aluminum, magnesium, beryllium and approach
sodium. Steps for an engineering approach include
• Class K—fires involving vegetable or animal cooking oils or Identification of possible accident scenarios
fats; common in commercial cooking operations using deep Analysis of consequences resulting in accidents
fat fryers Evaluation of alternative protection methods

Scenario Identification
– Pre-incident situations (start-up, maintenance, shutdown)
– Ignition source
– Ignited material
– Flaming or smoldering combustion
– Fire spread and heat release rates of ignited material
– Fire spread to secondary combustibles
• Consequence Analysis
– Property damage or loss
– Personnel injury or fatality
– Interruption of operation continuity
– Explosion damage (i.e., surrounding community)

• Evaluation of alternative protection methods


– Effectiveness (e.g., prevention of life/property loss)
– Benefits (e.g., financial, continuity of operation, environmental)

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Historic data on US fires prior to


2003
Number of >$30M % of U.S. Large Type of Fire/Explosion % of Incidents Example
Type of Facility
Losses Loss Fires
Warehouses 17 27% Flammable Liquid 17% GM Livonia, Sandoz Basel

Petroleum Refineries 12 19% Plastic Storage 12.5% Ford Cologne Warehouse

Power Plants 5 8% Dust Explosion 9% Malden Mills

Chemical Plants 5 8% Vapor Cloud Explosion 8% Phillips Petroleum

Grain Elevators 3 Gas Explosion 5% Ford Rouge Powerhouse

Textile Plants 2 Electrical Cable 5% Ameritech Hinsdale

Telephone Exchanges 2 Aerosol Products 5% K Mart

Ink Manufacturing 2 Gas Fires 5% Gas Turbine Fire, VA

Aluminum Plants 2

Ignition sources in large loss fires

Type of Facility # of Incidents # of Fatalities Example

Petrochemical
10 726 – 967 Pemex, Mexico City
Plant
Garment Factory in
Factories 9 549 – 606
Bangladesh
Offshore Oil/Gas
2 203 Piper Alpha, North Sea
Platforms
Jennings, Oklahoma
Fireworks Facility 5 145
USA

Time Distribution of large loss fires


Ignition sources in large loss fires
from NFPA data on 338 Fires in
1985

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Status of automatic suppression Status of automatic detection


systems in 1987 large loss fires systems in 1987 large loss fires
(NFPA Journal, 1988) (NFPA Journal, 1988)

Automatic Detection System Status Number of Fires


Automatic Sprinkler System Status Number of Fires
Not Installed 19
Not Installed 14
Functioned as Designed 4
Overpowered by Fire 7
Not in Area of Fire Origin 1
System Shut Off Before Fire 2
Installation Incomplete 1
Not in Area of Fire Origin 3
Unknown 3
Damaged by Explosion 1
Total 28
Unknown 1
Total 28

Ventilation System Ventilation System

Ventilation System Construction Considerations


• Structural and thermal properties of construction
material
• Fire resistance analytical calculations
• Fire resistance testing for listing
• Fire wall design and loss experience
• Insulated metal deck roofing
• Water spray protection of structural steel
• Protective insulation materials on structural steel

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Storage: Flammable Chemicals Storage Incident


• Toulouse, France (September 2001)
• Chemical properties must be considered – AZote Fertilisant (AZF)
– Flash point – Manufactured fertilizer
– Auto-ignition temperatures – 300 tons of ammonium nitrate stored onsite (2,000 ton capacity)
– Extinguishability • Explosion left a crater 70m long, 40m wide, 6m deep
• Poor maintenance contributed to the incident
• Storage tanks • Mislabeled 500 kg container sodium dichlorisocynate accidently
– Capacity stored with ammonium nitrate
– Tank spacing • Reacted in humid weather to form nitrate trichloride
– Emergency ventilation • 29 fatalities
– Fire suppression • 2,500 seriously wounded
– General designs should be approved to meet specifications • ~60 – 70% of the city’s windows shattered, causing injuries
(such as FM Global – Factory Mutual) • $2Billion USD damages paid

Storage Considerations
• Combustible materials
– Quantity (e.g., rolls, drums)
– Type (e.g., liquids, powders, gases)
– Mixed commodities
• Effective measures to protect against fires
– Suppression systems
• Water
• Dry-chemical
– Spacing of discharge points (e.g., sprinkler heads)
Toulouse
http://oliaklodvenitiens.files.wordpress.com/2011/09/azf002.jpg – Limit ignition sources
– Remove unnecessary combustibles

The following table illustrates the types of extinguishers, fire classes for which each is used and the
Fire Extinguishers limitations of each extinguisher.

• There are different types of fire extinguishers designed


to put out the different classes of fire.
• Selecting the appropriate fire extinguisher is an
important consideration for a roofing contractor.
• The wrong extinguisher actually may make a fire
emergency worse.
• For example, failing to use a C-rated extinguisher on
energized electrical components may endanger workers
by causing the extinguishing material to be electrified
by the energized components that are on fire.
• C-rated fire extinguishers put out the fire by using a
chemical that does not conduct electricity.

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Using Fire Extinguishers


• When using fire extinguishers, employees
should employ the “PASS” system of early-stage
firefighting.
• P—Pull the pin on the extinguisher
• A—Aim at the base of the fire
• S—Squeeze the handle
• S—-Sweep at the fire, moving from side to side
• Employees should be instructed that if a fire
cannot be extinguished using one full
extinguisher, they should evacuate the site and
let the fire department handle the situation.

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