I/EC A
SAFETY
W O R K B O O K
F E A T U R E
by S. M. MacCutcheon,Dow Chemical Co.
Fire Prevention and Control Good design of buildings and incorporating safety ideas from your own company personnel, insurance companies, or consultant specialists are best ways of preventing fires
CHEMICAL
INDUSTRY'S
experience
with fires a n d explosions is a m a t t e r of continuing concern to progressive m a n a g e m e n t . While there is some variation in t h e over-all picture from year to year, large-loss fires in the industry annually reflect t h e severe fire-hazard potential in t h e n a t u r e of the products handled. I n addition, high-value equipment a n d raw material add significantly to the dollar losses on m a n y chemical industry fires. Fire safety a n d personal safety are literally hand-in-glove problems. Efficient operation c a n b e attained only through paying t h e proper a m o u n t of attention to both factors of the loss prevention picture, a n d , actually, the basic principles are t h e same. T h e physical a n d chemical properties of t h e r a w materials—i.e., flammable liquids a n d reactive chemicals—mean that a high hazard p o tential exists. Added to this factor is t h e n a t u r e of the operations used in processing the chemicals—i.e., exothermic reactions, creation of static charges through pouring of liquids or solids, a n d high pressure a n d high t e m p e r a t u r e conditions. It is n o t o u r intent to delve into the technical aspects of the chemical industry fire hazards or detailed means for controlling these hazards, but to stress the need for recognition of t h e problem a n d to review some basic principles of control measures.
Management's Responsibility Safety, fire as well as personal, is a m a n a g e m e n t responsibility. Success of any loss control program is almost directly proportional to t h e active participation b y m a n a g e m e n t in carrying out this responsibility. Size of t h e operation is never a factor in the importance of management responsibility. National Fire Protection Association reports include a large n u m b e r of serious and costly " c h e m i c a l " fires involving plants or operations where the total personnel is less t h a n 100. Equipment and Design E q u i p m e n t a n d building design is a most significant consideration following t o p m a n a g e m e n t acceptance of responsibility. H e r e the technical skill of t h e fire protection engineer is of great value. Any list of design factors, in considering adequate fire-loss control measures, would approximate t h e following points which a r e , in part, quoted from a talk, "Case Histories of Explosions in Chemical a n d Allied Industries," by Miles Woodworth, flammable liquids field engineer. Outside construction of process units wherever feasible. Adequate process and building relief and/or explosion venting. Installation of an automatic sprinkler system, based on appropriate risk evaluation. Design of electrical installations to ensure compliance with the N.F.P.A. Electrical Code.
Process unit design to ensure controllable exposures in case offire: Dikes, curbing, drains, spacing Fire-resistive tank supports Fixed water spray system or provision for flooding with an inert gas Provision for ensuring positive agitation, cooling, and other process variables when these conditions are critical. Isolation of process controls, including complete physical separation of the process and the controls, where this is appropriate. Proper design is a basic factor in the over-all approach to fire-loss control. Without it, all other factors are a p t to be ineffective and, therefore, costly. T h e experience of trained engineering personnel should be enlisted on each of the designated design problems. Your own fire protection specialist, insurance company personnel, or consultant specialists can contribute immeasurably in providing t h e necessary know-how and techniques of modern fire prevention and control. Personnel Training Operating procedures a n d t h e training of personnel t o follow established procedures is of extreme importance following assurance that fire safety has been designed into the process equipment. As in personal injury accidents, chemical plant fire experience has a very high proportion of incidents which are the direct result of h u m a n error. H u m a n mistakes can almost always be traced back to either a lack of proper operating procedures VOL. 49, NO. 12 ·
DECEMBER 1957
81 A
DOW CORNING
SAFETY
SILICONE DEFOAMERS
have proved their efficiency and versatility in countless applications. For example : 1 O U N C E KILLS F O A M I N
• · ·
Û 6 2 5 , 0 0 0 lb sodium b r o m i d e crystallization solution
or failure to follow the recognized proper procedures. H e r e again it is wise to consider the extreme hazard potential of the materials a n d processes incorporated in chemical manufacture. Recognition of this fact makes seemingly rigid a n d stringent operating procedures a logical a p p r o a c h to the fire prevention problem. T h e enforced use of a welding permit is a n example in point. Because of the high hazard potential a rigid control on all field welding is a must in chemical processing plants. This also holds true in other operating and maintenance procedures. Carefully worked out operating instructions should be p u t in written form. O p e r a t i n g personnel must be trained to follow these instructions to the letter. A valuable technique in instruction is to include the "reasons w h y " a given sequence is insisted on, or a given set of temperature a n d pressure conditions must be maintained.
6 2 5 0 , 0 0 0 lb molasses, v a t dye s o l u t i o n , p i c k l i n g solution, t a l l oil
trioxide
6 125,000 lb phenolformoldehyde, urea formaldehyde, asphalt, starch sizing
4 62,500
lb
soft drinks, 7 0 % caustic liquor, black liquor, sulfuric acid pickling bath
Just a few drops of a Dow Corning SILICONE DEFOAMER can prevent mountains of foam . . . enabling you to utilize full productive capacity and put your processing into high gear. What's more, when you control f o a m , you eliminate the mess a n d waste of boilovers. Whatever your foaming problem, a Dow Corning SILICONE DEFOAMER will help solve it at amazingly low cost.
^^^_
FREE SAMPLE and INFORMATION— To receive a generous trial sample of a Dow Corning Silicone Defoamer, return coupon below or write on your letterhead. No obligation, of course.
f i r s t in silicones
D o w
C o r n i n g
CORPORATION MIDLAND.
6424
my foamer is
NAME Oil system TITUE
Aqueous sysrem_
COMPANY
Other
Food products
CITY
82 A
ZONE
STATE
INDUSTRIAL AND ENGINEERING CHEMISTRY
MICHIGAN
Fire C o n t r o l
So far we have talked mainly about fire prevention, but fire control (fire extinguishment, fire fighting) is also a n important p a r t of the program. Despite all the recognized prevention techniques, fires still do occur and appropriate control measures to be most effective must be planned ahead of the fire. Design again comes into the picture. Original design is based on the premise t h a t fires will start, but that the resulting d a m a g e can be kept to a n acceptable minimum. O p e r a t o r training is also important. Practically any chemical plant can cite instances in which extinguishment of a relatively small fire by trained personnel avoided a major fire, personal injury, a n d property loss. T r a i n i n g of all operating a n d maintenance personnel in the proper use of first aid fire fighting equipment is a necessary first step. T h e establishment of a fire fighting brigade or d e p a r t m e n t , the necessary larger scale equipment, and the appropriate training techniques are additional specific steps to be taken. Any a m o u n t of help required in these areas is readily available from such sources as the National Safety Coun-
cil, the National Fire Protection Association, and the Manufacturing Chemists' Association.
GK
for the PROCESS INDUSTRIES
Cooperation at Local Municipal Level
Local municipal fire fighting organ izations must be taken into your confidence as a protection to your c o m p a n y a n d to personnel of the local fire d e p a r t m e n t . You will never gain by failing to cooperate with one or more of these groups. T h e municipal d e p a r t m e n t will be willing to accept your evaluation of proper fire fighting techniques u n d e r your special circumstances, b u t they will never accept a n at titude of, " Y o u stay out because we c a n ' t divulge our hazards or how to combat t h e m . " T h r o u g h plant m a n agement's taking the initiative in developing liaison with the local fire d e p a r t m e n t , you can readily demonstrate your staff's ability to handle chemical problems and better equip the municipal group to combat a fire if their help is required. T h e value of m u t u a l aid plans, developed with nearby plants, utili ties, a n d governmental agencies, should also be mentioned. T h e impact of poor public re lations at the time of a large fire or explosion is necessarily a source of real concern to chemical plant management. A "poor press" results more often from industry's improper handling of the story of a serious fire t h a n from the actual severity of the fire or explosion. T h e importance of a d e q u a t e fire protection a n d control measures must be recognized by all chemical m a n u facturers and processors. A bad experience by any one segment re flects on the entire industry. T h e present experience m a y be thought of as favorable when considering the potential, but must be looked upon as subject to improvement w h e n individual fires are examined and causes determined.
CLAYS and TECHNICAL SERVICE
If you are l o o k i n g for a ' l o w cost, insoluble, surface active powder of high purity, a Hydrite Kaolinite may meet your requirements. These kaolinites are available in a wide variety of con trolled particle sizes and specific surface area. Hydrite Kaolinites are selectively mined hydrated aluminum silicates used exten sively in the process industries. A m o n g the many materials in which they are used are: adhesive* ceramics
ink insecticides
leather paint paper petroleum textiles
pharmaceuticals plastics protective coatings rubber
Manufacturers w h o wish to determine the practicability of using kaolin clays in their products are invited to avail themselves of the extensive research facilities of the G K Technical Service Department.
GEORGIA KAOLIN COMPANY 4 3 3 North Broad St., Elizabeth, N . J.
JMy eyesl My face!
Provide instant M A U f Q relief w i t h . . . Π H f f Ο EMERGENCY EYE and FACE WASH FOUNTAINS Eye a n d f a c e h a z a r d s a r e i n e v i t a b l e
in
i n d u s t r y . . . so take positive steps to reduce the extent of injury and minimize insurance claims. HAWS Emergency Eye and Face Wash Fountains flood
contaminated areas with water — instantly
ridding face and eyes of caustics, chemicals and dan gerous particles. This instant relief may well pre vent permanent damage — bridging the gap until medical aid arrives. Install extra safety —HAWS Emergency Fountains and Drench Showers. Write today for detailed
infor
mation on the complete HAWS line of emergency facilities. HAWS DRINKING FAUCET COMPANY, 1443 Fourth Street, Berkeley 10, Calif.
Our authors like to hear from readers. If you have questions or comments, or both, send them via The Editor, l/EC, 1155 16th Street N.W., Washington 6, D. C. Letters will be forwarded and answered promptly.
pr
Model 8933:
Face spray ring acts simultaneous! with eye-wash, sending controlled streams of water from specially de signed twin fountain heads.
HAWS VOL. 49, NO. 12
·
DECEMBER 1957
83 A
