GabeM-Another Type of Hazard Analysisassevirtualsymposium.pbworks.com/f/GabeM-Another Type of Hazard...o Sewage Gas o Welding Gases (Acetylene, Propylene, ... • Similar to training

2/28/2011

1

The Fire Prevention Plan: Another Type of Hazard Analysis

Gabriel Miehl CSP, CFPSAssistant Administrator

ASSE Fire Protection Practice Specialty


FIRE IS GOOD…USUALLY


Where Fires Occur: Basic Industrial Buildings

http://www.usfa.dhs.gov/downloads/pdf/statistics/fa_325.pdf

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Where Fires Occur: Basic Industrial Buildings

www.usfa.dhs.gov/downloads/pdf/statistics/nonresidential_building_fires.pdf ‐ 2010‐08‐17


Where Fires Occur: Manufacturing Buildings

www.usfa.dhs.gov/downloads/pdf/statistics/nonresidential_building_fires.pdf ‐ 2010‐08‐17


Fire Costs: Non‐Residential Buildings

http://www.usfa.dhs.gov/downloads/pdf/statistics/nonres_bldg_fire_trends.pdf

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Fire Costs: Non‐Residential Buildings

http://www.bls.gov/iif/oshwc/cfoi/cfch0006.pdf


Regulatory Requirements: OSHA

http://www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=STANDARDS&p_id=12887


Regulatory Requirements: OSHADo you need an FPP under 1910.38(b)?

Are you required to complywith:• 1910.1047 Ethylene Oxide • 1910.1050 Methylenedianiline• 1910.1051 1,3 ‐Butadiene ?

Are you required to comply

http://www.osha.gov/OshDoc/Directive_pdf/CPL_2‐1_037.pdf

with 1910.157 (Portable Fire Extinguishers)?

Do all of your employeesevacuate immediately duringa fire emergency?

No requirements for an FPP, other requirements under 1910.157 apply.

Do you have fire extinguishers in the workplace?

Fire extinguishers are notintended for employee use.

Develop a FPP

NO

YES

YES

NO

YES

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The Hazard Analysis:Per 29 CFR 1910.39:

1. A list of all major fire hazards (THIS IS THE HAZARD ANALYSIS). • Proper handling and storage procedures • Potential ignition sources,

http://www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=STANDARDS&p_id=12887

g ,• Fire protection equipment

2. A housekeeping plan

3. Preventative maintenance procedures

4. Identification of persons responsible for PM and housekeeping.

5. A training program.


The Hazard Analysis:“A technique that focuses on job tasks as a way to identify hazards before they occur. It focuses on the relationship between the worker, the task, the tools, and the work environment”. I

FPP Key Elements:y

• Recognizing the fuel sources and ignition sources that could be present in the workplace,

• How these fuel and ignition sources can interact,

• What controls are needed to prevent interaction or minimize the effects of interaction.

Gasseso Fuels (Natural Gas, Propane, LNG,

etc.)o Sewage Gaso Welding Gases (Acetylene,

Propylene, etc.)o Production Aids (Anhydrous

Ammonia, Hydrogen, etc.)

Liquidso Solvents (Acetone, MEK, Alcohols,

etc.)o Fuels (Gasoline, Diesel, etc.)o Paintso Oils/Lubricantso Organic Peroxideso Medical (Ethylene Oxide)

Solids (Cellulosic)o Wood (Pallets, Packaging Material)o Paper/Cardboardo Christmas Trees (Decorations)

Fibers/Textiles Plastics/Rubbers Explosives/Blasting Agents


The Hazard Analysis: Fuel Sources (NFPA HB Sec. 3 & 4)

Fibers/Textileso Natural Fibers (Cellulosic-Cotton,

Linen, etc.)o Man Made Fibers (Nylon, Polyester,

etc.)

Plastics/Rubberso Foams (Styrofoam)o Filmso Resinso Sheetso Natural Rubberso Synthetic Rubbers

Explosives/Blasting Agentso High Explosives (TNT,

nitroglycerine, etc.)o Low Explosives/Propellants (Black

Powder, Solid Rocket Fuels, etc.)o Blasting Agents o Water Gels, Slurries, Emulsions

Metalso Calciumo Lithiumo Magnesiumo Potassiumo Sodiumo Zinc

Dusts:o Agricultural (Flour, Sugar, Coffee,

etc.)o Carbonaceous (Charcoal, Coal, etc.)o Metals (Aluminum, Iron,

Magnesium, etc.)o Miscellaneous (Paper)o Plasticso Drugs (Aspirin, Vitamin C)

Structural Materialso Wood Beams/Joists/etc.o Interior Finisho Floor Finisho Insulating Materials (Polyurethane,

Polystyrene)

Other:o O2 Enriched Atmospheres (> 21%)

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Chemical • Heat of Combustion: Fuels burned creating a heat

source- ovens, torches, boilers, water heaters, matches, cigarettes, OPEN FLAMES, etc.

• Spontaneous Heating: Materials that can spontaneously combust-

oil soaked rags, wood chips, agricultural products (wet hay), coal, charcoal, paint and paint scrapings, and fiber products (stored before cooled-

Electrical • Heating Equipment (Resistance, Dielectric,

Induction)• Lighting Equipment (Hot Surfaces)• Faulty/Overloaded Electrical Equipment (including

overheated equipment)• Arcing• Static Electricity• Lightening


The Hazard Analysis: Ignition Sources (NFPA HB Sec. 3 & 4)

“preheated”.• Heat of Decomposition: Materials that decompose

when heated beyond a critical temperature-acetylene, nitrocellulose, peroxides.

• Incompatible Materials: water reactive, acids/bases, etc.

• Equipment Used in Rated Atmospheres.

Mechanical • Friction Heat: Heat developed when two surface rub

together- conveyor belt slipping against a pulley, metal contamination of grain or textile handling machinery, HOT SURFACES.

• Friction Sparks: Sparks developed when two surface impact- grinding operations, hammering, shoe nails on a concrete floor.

• Heat of Compression: The heat released when gas is compressed- the “diesel effect”.

• Molten Material

Nuclear Heat Energy: The energy released is enough to heat steam for electrical generation.


The Hazard Analysis: Fuel Source Inventory

Storage Location Material Amount/Volume1 B6-Bay A Col 4,

“HAZMAT” RoomOxygen 4 X HP250

Cylinders2 B6-Bay E Col 4, Isopropyl Alcohol 4 X 5 Gallon Pails2 B6 Bay E Col 4,

Receiving DockIsopropyl Alcohol 4 X 5 Gallon Pails

on a Pallet3 B6 Bay E Col 1,

Receiving DockIdle Wood Pallets (36” X 36”)

3 X 8’ Stacks


The Hazard Analysis: Ignition Source Inventory

Ignition Source Location

Ignition Source Cause

1 B6-Bay A Col 4, “HAZMAT” Room

Hot Surface Steam Pipes at Ceiling

2 6 C l 4 l i l2 B6-Bay F Col 4, Receiving Dock

Hot Surfaces/Overheating/Arcing

Electrical Transformers

3 B6 Bay F Col 1, Receiving Dock

Hot Surfaces/Sparking

Bench Grinder

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The Hazard Analysis: Mapping

BAY A BAY B BAY C BAY D BAY E BAY F

BUILDING 6 FPP MAP N

I‐ B. Grinder

COL 1

COL 2

COL 3

COL 4

Emergency Exit

HAZ Storage

Receiving Dock

I‐Steam Pipes I‐X‐FormerF‐02

F‐IPA

F‐Wood Pallets


The Hazard Analysis: Developing Controls‐ FIRE

FUEL

OXYGEN

HEAT

Chemical Reaction

training.fema.gov/EMIWeb/downloads/ IG‐CERT‐Unit2Rev2.doc


The Hazard Analysis: Developing Controls‐ Dust Issues

http://www.osha.gov/dts/shib/shib073105.pdf

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The Hazard Analysis: Control HierarchyControl Ignition Sources

ORControl Fuel/Ignition Interaction

ORControl Fuel Sources

• Eliminate Ignition SourcesOR

• Control Heat Transfer to Fuel Sources

• Control Heat Transfer to Fuel Sources:

1. Separation OR2. Barriers

AND• Control Heat Transfer Process to

• Eliminate Fuel SourcesOR

• Control Ability of Fuel to Ignite1. Control Fuel Properties OR2. Control the Storage Environment

Adapted from NFPA Fire Protection Handbook‐ 18th Ed. Section 1‐38

Fuel Sources:1. Convection AND2. Conduction AND3. Radiation

AND• Control (Contain) Fuel Sources1. Barriers OR2. Separation

Examples:• Indirect heating sources (steam versus

direct fire)• Torch Heating to Induction Heating• Temperature Controls

Examples:• Spark Catchers• Double Wall Metal Piping• Guarding by Location• Air/Fuel/Pressure Safety

Interlocks• Chimney Cleaning • Ventilation Interlocks• Hot Work Permit Programs

Examples:• Material Substitution (Water Base

vs. Solvent Base Parts Washers)• Fire Resistive Air Filters• Inerting Atmospheres


The Hazard Analysis: Control InventoryStorage Location Material … Control


Oxygen • Rated fire wall.• No cell phone/radio use.• Foam fire suppression

system.2 B6-Bay E Col 4,

Receiving DockIsopropyl Alcohol • Approved flammable

storage cabinet (C/A).3 B6 Bay E Col 1,

Receiving DockIdle Wood Pallets (36” X 36”)

• Storage height limited to 8’ stacks, maximum of 4 stacks.

• Protected by an automatic sprinkler system.

Ignition Source Location

Ignition Source Cause Control


Hot Surface Steam Pipes at Ceiling

• Steam pipes are fully insulated and located at ceiling level to prevent contact with material.


The Hazard Analysis: Control Inventory

2 B6-Bay F Col 4, Receiving Dock

Hot Surfaces/ Overheating/ Arcing

Electrical Transformers

• PM Program involving regular thermographic imaging and oil analysis.

• Transformer located in fenced area.

• Regular housekeeping of the area surrounding the transformer.

3 B6 Bay F Col 1, Receiving Dock

Hot Surfaces/ Sparking

Bench Grinder • Grinder located in an “approved” hot work maintenance location.

• Grinder located behind weld curtains.

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The FPP: Housekeeping

Housekeeping is defined by the Encarta World English Dictionary as:“management of property and equipment: the management and upkeep of equipment and property for a business or other 0rganization”.

G lGoals:

•Minimize locations where a fire can start.

•Minimize the potential for fire to spread.

•Minimize the potential for dust explosions.

•Minimize accumulations of spilled materials.

•Minimize the potential for spontaneous combustion.


The FPP: Housekeeping

Typical areas of concern for housekeeping include:

• Floors/Horizontal Surfaces

W t R t l• Waste Receptacles

• Spill Response

• Storage

• Combustible Dusts

• Vents/Ducts:


The FPP: Equipment Maintenance

Preventative Maintenance is defined by Webster’s Dictionary as “To bring down a machine for inspection or test purposes.”

Goal:

• Ensure that a piece of equipment does not become a potential ignition source.

Issue:

• Equipment maintenance programs are often process specific.

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The Hazard Analysis: Equipment Maintenance

Typical Areas of Concern for EM:

• Spray Application (of Flammable/Combustible Materials)

C S t• Conveyor Systems

• Ovens/Heaters

• Boilers

• Electrical Systems

• Safety Devices:


The Hazard Analysis: Training

Purpose:

• Inform employees of the fire hazards in their work area and the steps that must be taken to minimize these hazards.

How:

• Developed directly from the hazard analysis.• Similar to training development through JSA/JHA/PPE Analysis.

Frequency:

• At initial assignment; • Workplace Changes;• Process Failure


The FPP: Training

Purpose:

• Inform employees of the fire hazards in their work area and the steps that must be taken to minimize these hazards.

How:

• Developed directly from the hazard analysis.• Similar to training development through JSA/JHA/PPE Analysis.

Frequency:

• At initial assignment; • Workplace Changes;• Process Failure

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The FPP: Training

Issue:

• Training is also often process specific.• Knowledge of the process hazards is critical.D t f t i t t k (M t f Ch )• Do not forget maintenance tasks (Management of Change)

Examples:• Ovens and Furnaces‐ Air/fuel mixtures, ignitions sources and temperatures, gases, functions of controls, functions of safety devices, emergency shutdown procedures.

• Combustible Metals‐ Special hazards (extinguishing information).

• Hydraulic Systems Maintenance‐ Threaded connections vs. armored or double wall hose.


The FPP: HOT WORK

Per the NFPA, from 2003‐2006:

• 5,580 reported structure fires in the US

http://www.nfpa.org/assets/files/PDF/Torches/FactSheet.pdf

• 2,210 Residential / 3,370 Non‐Residential

• 22 Civilian Deaths‐ 7 Residential/ 15 Non‐Residential

• 223 Civilian Injuries‐119 Residential / 103 Non‐ Residential

• $208 MM Direct Costs‐$110 MM Residential / $98 MM Non‐Residential


The FPP: HOT WORK

http://www.uscg.mil/forms/cg/CG_4201.pdf

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The FPP: HOT WORK



The FPP: HOT WORK



The FPP: Practice Makes Perfect‐Hot Work

http://www.csb.gov/videoroom/detail.aspx?VID=44

Click the PLAY button to start the video. The video will play in a new window.

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The FPP: Practice Makes Perfect‐Hot Work

ID Storage Location

Material Amount/ Volume

Control

1 Bulk Tank Crude Oil‐POSSIBLE

Multiple BulkOil Tanks

• Purge process to eliminate liquid

Fuel Source Inventory

FLAMMABLE VAPOR

and vapor.• Blank open piping.• Gas detection equipment.

ID IgnitionLocation


1 At the top of the bulk tank.

Hot Sparks Welding Tasks

• Blank open piping.• Hot Work Permit

Ignition Source Inventory


The FPP: Practice Makes Perfect‐Combustible Dust

http://www.csb.gov/videoroom/detail.aspx?VID=44

Click the PLAY button to start the video. The video will play in a new window.


The FPP: Practice Makes Perfect‐Combustible Dust

ID Storage Location

Material Amount/ Volume

Control

1 VariousHorizontal

Phenolic Resin Residue/Debris

Maintain < 1/32”

• Minimize horizontal surfaces.

Fuel Source Inventory

Surfaces • Rated vacuum systems.

• Housekeeping inspections.

ID IgnitionLocation


1 Oven Open Flame Burners • Thermostats• Door Interlocks• Shut‐Down Procedures

Ignition Source Inventory

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The FPP: Conclusion

A Fire Prevention Plan is a key part of preventing fires in the workplace:

• Knowledge of process and material hazards is key.• Teamwork to lift the blinders.• Housekeeping‐Individual process collectively pursued.• EQ to prevent the E from being an I.• Training‐ Operators need to understand.

IT IS THE RIGHT THING TO DO!!!CEU Scavenger Hunt

Prevention


CitationsNFPA.org. http://www.nfpa.org/assets/files/PDF/IndustrialFactSheet.pdf .web. 2‐1‐2011

OSHA.gov. 29 CFR 1910.157http://www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=STANDARDS&p_id=9811 .WEB. 2‐1‐2011

OSHA.gov. 29 CFR 1910.39http://www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=STANDARDS&p_id=12887 .WEB. 2‐1‐2011

OSHA.gov.OSHA Fire Safety Advisor. http://www.osha.gov/dts/osta/oshasoft/softfirex.html .WEB. 2‐1‐2011

OSHA.gov. OSHA CPL_2‐1_037. http://www.osha.gov/dts/osta/oshasoft/softfirex.html .WEB.2‐1‐2011

OSHA.gov. OSHA Publication 3071‐Job Hazard Analysis.http://www.osha.gov/Publications/osha3071.html .WEB. 2‐1‐2011

ILO.org.http://www.ilo.org/safework_bookshelf/english?content&nd=857170508 .WEB. 2‐1‐2011

fmglobal.com. http://www.fmglobal.com/fmglobalregistration/Vshared/FMDS0700.pdf .WEB. 2‐1‐2011

Encarta® World English Dictionary[North American Edition] © & (P) 2009 Microsoft Corporation http://www.bing.com/Dictionary/search?q=define+housekeeping&FORM=DTPDIA&qpvt=housekeeping%2c+definition. WEB. 2‐1‐2011

webster‐dictionary.org. http://www.webster‐dictionary.org/definition/preventive%20maintenance .WEB. 2‐1‐2011


Citationsusfa.dhs.gov. http://www.usfa.dhs.gov/downloads/pdf/statistics/fa_325.pdf. WEB.2‐14‐2011

usfa.dhs.gov. www.usfa.dhs.gov/downloads/pdf/statistics/nonresidential_building_fires.pdf ‐ 2010‐08‐17. WEB. 2‐14‐2011

Usfa.dhs.gov. http://www.usfa.dhs.gov/downloads/pdf/statistics/nonres_bldg_fire_trends.pdf. WEB. 2‐14‐2011

bls.gov. http://www.bls.gov/iif/oshwc/cfoi/cfch0006.pdf. WEB. 2‐14‐2011

Training.fema.gov. training.fema.gov/EMIWeb/downloads/ IG‐CERT‐Unit2Rev2.doc. WEB. 2‐14‐2011

osha.gov. http://www.osha.gov/dts/shib/shib073105.pdf. WEB. 2‐14‐2011

uscg.mil. http://www.uscg.mil/forms/cg/CG_4201.pdf . WEB. 2‐14‐2011

csb.gov. http://www.csb.gov/videoroom/detail.aspx?VID=44. WEB. 2‐14‐2011

csb.gov. http://www.csb.gov/videoroom/detail.aspx?VID=44 .WEB. 2‐14‐2011

National Fire Protection Association. Fire Protection Handbook (18th Ed.). 1997. Print

Documents

GabeM-Another Type of Hazard Analysisassevirtualsymposium.pbworks.com/f/GabeM-Another Type of Hazard...o Sewage Gas o Welding Gases (Acetylene, Propylene, ... • Similar to training