Chemical Process Safety

Professor Shishir Sinha

Department of Chemical Engineering
Indian Institute of Technology Roorkee
Lecture - 30
General Design Methods to Prevent Fire
Welcome to the next module of design to prevent the fire and explosion.

(Refer Slide Time: 00:48)

In this module we will discuss the general design methodology to prevent the electrostatic
ignition. We will discuss about the relaxation that how the charge is with the enhanced inlet
area we can reduce the impact of static charge. We will discuss the bonding and grounding.
What is the role of dip piping in the static electricity generation. Increasing the conductivity
with the additives, we will discuss about it, how we can increase the conductivity. Explosion
proof housing and designing or layouting, we will discuss about this.

(Refer Slide Time: 01:15)

So, let us have first aspect that is general design methodology to prevent the electrostatic
ignition. Usually methods generally used while handling the liquid that is the reducing the rate
of charge generation must reduce the flow rate so that the generation and accumulation of static
charge is minimized. Then increasing the rate of charge relaxation so relaxation tanks after
filters, enlarged section of pipe before entering the tank so once you enlarge the section then
the charge density will be on the lower side. So, the impact of destructiveness of that particular
charge would be on the lower side.

So methods generally used when we handle the powders especially in some industrial
establishments you need to handle the powders and during the previous module we have seen
that while we are handling the powder then there are prominent chances of generation of static
electricity. So, they include the charge reduction by means of a low energy discharge so when
dangerous discharges cannot be eliminated then prevent the possibility of an ignition by
maintaining oxidant levels below the combustible level or inerting or by maintaining the fuel
level below the LFL or above the UFL.

Now remember this above the UFL is again a very undesirable situation because at any point
of time there may be a chance that it may reach the range of LFL and UFL, so it can create a
dangerous problem. So, it is always advisable to maintain the low oxidant level, or you can
seek the knowledge of LFL so that it can be below the LFL range.

(Refer Slide Time: 03:23)

Now, there are certain special design features for the prevention of electrostatic ignition. Sparks
usually they are prevented by grounding and bonding so grounding and bonding they are very
useful and common phenomenon for elimination of the hazard of electrostatic ignition. Now,
they prevent two metallic objects from having the different potential, prevent the existence of
isolated metal parts or objects.

So, propagating brush discharge are prevented by keeping nonconductive surfaces or coatings
thin enough or conductive enough to have a breakdown voltage roughly below 4 kiloVolts.
They are also prevented by keeping the metallic backings grounded, to eliminate accumulation
of high-density charge on interface and counter charge on non-conductor surface.

(Refer Slide Time: 04:12)

Conical pile discharges they are prevented by increasing the conductivity, by addition of certain
additives, we will discuss in due course of time, by decreasing the chare rate below around they
say 0.5 kilogram per second or by using the containers with volume less than 1 meter cube.
Now the most effective, remember the most effective way is inerting. So, if your inerting is
efficient then definitely you can avoid the hazard of electrostatic ignition.

So, brush discharges they are prevented by keeping the nonconductive surface thin enough or
conductive enough to have a breakdown voltage that is usually less than 4 kilovolt.
Nonconductive coatings with the thickness greater than 2 millimetre, however, capable of
brush discharge even with a U, less than 4 kilovolt. Now to prevent the brush discharge a
thickness of around 2 millimetre is necessary again, repeating it again that the most effective
way is inerting.

(Refer Slide Time: 05:23)

Now relaxation. Sometimes relaxation because the charge density is a very crucial point, so
relaxation is one of the most effective or you can say the effective tool to minimize the effect
of electrostatic ignition. So, when you are pumping fluids into a vessel through a pipe on the
top of the vessel, like this, the separation process produces a streaming current, like this, which
is the basis of charge build up.

Now it is possible to substantially reduce this electrostatic hazard by adding an enlarged section
of pipe just before entering the tank. It is just like this. You can have this enlarged section and
you may have the piping like this. So, this is the enlarged section and if you compare with this,
this is the enlarged section. So, the residence time in this relaxation section of pipe should be
about twice the relaxation time, determined using:

𝜀𝑟 𝜀0
𝜏=
𝛾𝑐

(Refer Slide Time: 06:40)

Another important aspect is bonding and grounding. The voltage difference between two
conducting materials is reduced to zero by bonding together. Now, in other words, one end of
a conducting wire to one of the materials and bonding the other end to the second material. So,
when comparing the set of bonded materials, the set may have different voltages. The voltage
difference between the set is reduced to zero by bonding each set to ground and that is by
grounding. So, bonding and grounding reduces the voltage of an entire system to ground level
or a zero voltage.

(Refer Slide Time: 07:22)

Now this is the pictorial explanation of this bonding and grounding. Now here, we have a
container which is duly grounded. Now this is the container and these two, these Bolt clamp,
type A and type B both are joined together, and this is the best example of bonding and
grounding.

(Refer Slide Time: 07:47)

Now here the grounding, this is the container and you are discharging certain liquid to a small
open pail, now here you can ground it or you can build the static grounding bus through which
you can discharge or you can eliminate the charge, whatever charge being generated it can be
eliminated, now here there are 2, you can see, this is bonded with these 2 clamps, this one is
bonded and charge, this charge is connected to this bus wire so that you can eliminate the
hazard of electrostatic ignition.
(Refer Slide Time: 08:41)

Now this is again a very common phenomenon that is accumulated charge remain in non-
conductive and non-grounded vessel. If your filling any vessel with any fluid, if it is not
properly been grounded or bonded then the charge will remain to the surface of this particular
vessel and whenever this particular vessel will come into contact to certain favourable
conditions then spark may generated. So be careful and adopt the concept of grounding.

(Refer Slide Time: 09:16)

Sometimes you may experience there are certain zones, those who have the accumulation of
these electrostatic charges and sometimes they are unnoticed, like this, you are having a non-
conductive line, a pipeline where the charge is accumulated at the surface, similarly you are
having may be a conductive line or may be some non-conductive line, the charge is
accumulated at the surface of these flanges, so, whenever the favourable condition achieves,
then definitely they may be in a position to produce the spark.

(Refer Slide Time: 10:00)

This is again, the best example of streaming charge effect. Now this particular lorry contains a
flammable liquid. Let us have some practical example of petrol or motor spirit, this lorry carries
the motor spirit so during the transit or during the transportation from the depot to the petrol
pump, it may have certain accumulated charges, either at the inner part like this at the surface
or over the fluid surface.

Now, when it tends to discharge this particular flammable liquid to the storage arena of a petrol
pump then there are certain metal surfaces or metallic surfaces, then it may have a favourable
condition for the generation of spark. Now during the transfer, you cannot avoid the formation
of certain vapours because they are inherent property attributed to vapour pressure.

Then the spark may be generated, and this spark may have the sufficient amount of energy so
that it can blown up the entire petrol station of the petrol pump. That is why to neutralize this
extremely charged and to neutralize the things you must ground this particular filling station
or filling pump whenever you are having, either you pre-ground it or you during the process of
unloading this particular tanker you make grounding in a continuous fashion.

(Refer Slide Time: 11:55)

Now, another aspect is that dip pipe. Usually this is an extended line or sometimes called a dip
leg or dip pipe which reduces the electric charge that accumulates when liquid is allowed to
free fall. While using dip pipe care must be taken to prevent the siphoning back when the inlet
flow is stopped. The method is to place a hole in the dip pipe near the top of the vessel. Another
technique is to use an angle iron instead of a dip pipe and let the liquid flow down to an angle
iron.

(Refer Slide Time: 12:38)

Now here it is the best example that how dip legs prevent the free fall and accumulation of
static charges. So before we discuss this one let us have what happened at the start-up. Suppose
I am having this vessel to be filled with flammable liquid and one option is that I am flowing
the liquid from the top like this so what happens there may be a chance of generation of charge
at the inner lining and over the surface of this liquid because they are having the larger area.

Now with the concept of a dip leg here you can see that this particular dip leg is just a few inch
or few distance away from the bottom of this one. So, by this way whenever the liquid is coming
out, electrostatic charge generation, the possibilities are on the lower side. So, by this way you
can minimize the generation of electrostatic charge or static charge built up. Now one problem
is there, and that problem is attributed to the siphoning.

Because whenever this liquid is coming at this level and suppose this particular thing is
connected to some other vessel, which is may be the filling vessel then there may be a chance
of reverting it back to the, this particular vessel. To avoid this siphoning back aspect, you may
put a hole to break the siphon. Now remember whenever you are filling there may be a chance
that the liquid may come out from this hole and it may create again the problem of generation
of static charge.

So, whenever you are encountering such type of a problem then you may have another remedy
for this one. You may put an angle iron which may be suitably grounded or bonded and you
can put the flow in such a manner that it is having the reduced flow live and it will align to this
angle iron bar so that the generation of static charges may be minimized. So, these are the
couple of methodology through which you can prevent the free fall and accumulation of static
charge by dip leg concept.

(Refer Slide Time: 15:22)

Now there is another possibility of spark or spark charge transfer. This is the vessel filling
operation, now there are three aspects, one is this one, another one is that the outer periphery
you may generate the charge and third one is that how we can reduce the impact of this
generation of spark. So, this figure, particular figure depicts that how we can minimize this
charge transfer and how we can minimize the effect of spark generation.

(Refer Slide Time: 16:02)

Another methodology is to increase the conductivity by the addition of additives. So, the
conductivity of non-conducting organic materials can sometimes be increased using the
additives, they are called the antistatic additives. Examples of antistatic additives include water
and polar solvents such as alcohol, etc. Water is effective only when it is soluble in the
offending liquid because an insoluble phase gives an additional source of separation and charge
build up.

(Refer Slide Time: 16:36)

Sometimes you need to encounter the problem of handling solid without flammable vapours
so here again you need to adopt the proper bonding and grounding aspect like here you can see,
these two are bonded each other. Now here before we go into detail, this particular solid is
being filled with this funnel to this particular reactor so while transferring this solid material
through this hopper or a funnel to this reactor there may be a chance of generation of static
charge.

Now as an engineer you must find out that what are the possible danger zones. One zone is this
container itself, another zone is this funnel itself and third zone is this reactor itself. So, you
can see that this particular vessel is properly bonded with this funnel, like this and this adjoining
is properly grounded, so by this way you can minimize the hazard of both this and this.

In the next aspect while you are transferring this material to this reactor obviously there will
be generation of certain electrostatic charge then this vessel is again grounded to minimise the
effect of this is electrostatic charge. So, you must find out that what are the crucial area where
you need to pay a proper attention.

Now charging the solid with non-grounded conductive shoes, they can result in a build-up of
charge. That is why they have put this bonding and grounding. Now this charge can accumulate
and finally produce a spark this may ignite the dispersed dust to avoid this kind of thing you
must find out the crucial area.

(Refer Slide Time: 18:53)

Sometimes you may need to handle another scenario where you cannot perform this type of
activity which we have discussed in the previous slide. Then you need to adopt the concept of
inerting. Now here you are handling with the flammable vapours so when your continuously
filling solids to this particular reactor, this is a solid liquid reaction so in that particular case the
chances of generation of charge are on the higher side and sometimes you may not be in a
position to ground it properly.

In that particular case you may need to have a proper supply line for interting so that whatever
vapours are being generated or whatever combustible mixture is being generated at the surface
of this particular liquid it may be properly inerted so that it cannot ignite because remember if
you are not attempting this type of thing then vapour or dust whatever is there, they may form
a flammable mixture and you are having sufficient electrostatic charge built up within the
vessel and at any point of time the spark may generate and the entire vessel may explode.

To minimize this particular effect, you need to have certain supply lines for inerting. So, usually
there are certain advisories and you know that here you are also having the solid which is being
filled to this particular reactor, it is properly bounded and grounded who are you, so usually
these type of things are being used when you are not in a position to have the additives, you
are not in a position to have a proper grounding methodology then go for inerting.

(Refer Slide Time: 21:01)

When you are acclimatized or you are bound to work under such scenario then you cannot
overlook the importance of explosion proof equipment and instruments all so it is advisory that
all electrical devices, they are having inherent ignition sources, so keeping in view of this fact,
you must design the methodology through which you use those explosion proof equipments
and instruments.

So, special design features are required to prevent the ignition of flammable vapour and dust.
The fire and explosion hazard is directly proportional to the number and type of electrical
powered devices in a process area. So, process area are divided usually in two major type
environment, XP and non XP, that is explosion proof and non-explosion proof.

(Refer Slide Time: 21:56)

Now, if flammable materials might be present at time in an area, it is designated XP that is
explosion proof required and if not present even under abnormal condition it is designated as
non-explosion proof required area, so that means you can avoid the installation of such safety
devices. So, for non-explosion proof required designated area open flames, heated elements
and other sources of ignition may be present because you can work it upon.

The housings are not designed to prevent flammable vapours and gases from entering but
designed to withstand an internal explosion and prevent the combustion from spreading beyond
the inside of the enclosure.

(Refer Slide Time: 22:45)

Now, how we can classify this explosion proof housing? This slide will discuss the
classification are usually defined on the basis of national electrical code that is based on United
States federal law and this is a function of nature and degree of the process hazards within a
particular area.

So rating methods, this include, Class I, Class II, Class III groups and groups from A to G and
division 1 or 2. So class I includes the location where flammable gases or vapours at present,
Class II same for the combustible dusts, Class III hazard locations where combustible fibers or
dusts are present, but not likely to be in suspension so that you can designate the different area
of plant in different classes.

(Refer Slide Time: 23:47)

Now the groups, they are designated to presence of specific chemical type and the chemicals
that are grouped have equivalent hazards like Group A acetylene or equivalent; Group B
hydrogen, ethylene; Group C carbon monoxide, hydrogen sulphide, Group D butane, ethane,
ethyl alcohol, Group E aluminium dust, Group F carbon black, Group G flour.

(Refer Slide Time: 24:18)

Now divisions because there are two types of divisions, division designations are categorised
in relationship to the probability of the material being within the flammable for explosive
region. Division I, probability of ignition is high; that is flammable concentrations are normally
present. Division II, the hazardous only abnormal conditions may be thermal run away
reactions or temperature based reactions, etc. Flammable materials are normally contained in
closed containers or systems.
(Refer Slide Time: 24:46)

Now, how we can design an explosion proof area? The first thing which comes into our picture
is ventilation. So proper ventilation, we have discussed this ventilation tool in industrial
hygiene, so proper ventilation is one of the methods used to prevent the fires and explosions.
The purpose of ventilation is to dilute the explosive vapours with air to prevent the explosion
and to confine the hazardous flammable mixtures. Both dilution and local ventilation applicable
for plants inside the building.

(Refer Slide Time: 25:21)

There are certain open-air plants so open-air plants are recommended because the average wind
velocities are high enough to safely dilute the volatile chemical leaks if any and that may exist
within a plant. Sometimes it may create a problem of unconfined vapour cloud explosion. So,
although safety precautions are always practiced to minimize leaks, accidental releases from
pump seals and other potential releases are the points under the consideration of this head.

There are certain plants inside building so local ventilation obviously purge boxes, elephant
trunks, etc you can use. Dilution ventilation when many small points of possible leaks they
exist, and you can use the dilution ventilation.

(Refer Slide Time: 26:13)

Usually need of ventilation is that aids in saving lives or assisting the saving life sometime,
sometimes assist in suppressing fire, assist in reducing the property damage so that is why
ventilation is extremely important.

(Refer Slide Time: 26:40)

Now while assisting in saving life this improves the visibility. Allows for the faster, sometimes
when there is a leak of any flammable or any kind of hazardous vapour the atmosphere or the
area may become little bit hazy, so ventilation may increase the visibility. Allows for faster
location of unconscious victims so that you can approach to them easily. Simplifies and
expedite the rescue operation because once the visibility is clear you can easily approach to
them. Makes conditions safer for firefighters and victims.

(Refer Slide Time: 27:19)

Now aids in suppressing fire in fire attack or extinguishment removes smoke, gases and heat
from building. Facilitates entry of firefighters because the visibility is on the higher side.
Reduces the obstacles that hinder the firefighters. Increases visibility for quicker location of
seat of fire.

(Refer Slide Time: 27:37)

In fire control they reduces the mushrooming, they reduces the flashover potential, they reduces
the backdraft potential and controls fire spreads etc.

(Refer Slide Time: 27:52)

They are helpful in reducing the property damage that permits the rapid extinguishment,
obviously the ventilation is very prominent in this aspect. Reduces water, heat and smoke
damage. Confines fire to an area. Allows salvage operation and fire control to take place
concurrently.

(Refer Slide Time: 28:24)

Now there are various factors those who determine the type of ventilation that is the building
type and design, confined building, unconfined building, etc. Number and size of wall opening,
how much you require. Number of stores and the floors. Number of staircases, shaft,
dumbwaiters, ducts, roof opening, etc. Because these are the certain guiding factors for this
one. Availability of exterior fire escapes and exposure involvement so these are the certain
factors those who determine what kind of or what type of ventilation you require.

(Refer Slide Time: 28:47)

Now ventilation opening location and size factors they depend on the availability of natural
opening because obviously for this opening you need not to pay any penny. Fire location, what
is the fire location. Building construction of what type. What is the wind direction although it
is not constant throughout. Fire phase, building Condition, what is the building condition,
sometimes building is quite old and because of the fire it may collapse down, or it may create
a problem sometimes when ventilation may initiate certain vibration which may be destructive
for building.

Building contents, what are the contents inside the building? What is the roof type, what is the
effect on fire, what is the effect on exposure, Attack crew's readiness, ability to protect
exposures, what is the size in the location, etc. So, these are the various things which you need
to look after.

(Refer Slide Time: 29:57)

So, in nutshell, in this particular module we summarise the things that ventilation removes
smoke, heat, toxic gases from burning building hence can save live and the reduced property
damage. Flashback or backdraft is caused by the addition of oxygen rich air to a smoke filled
and the fuel rich atmosphere.

Convection controls the spread of product of combustion. In convection, heated gas expands
and become less dense than the cooler gas, so you can minimize the problem. The proper
ventilation includes improved visibility, removal of heat and steam, reduction of backdraft.

(Refer Slide Time: 30:30)

Convection currents carry smoke, superheated gases to uninvolved areas so firefighter must be
able to recognise when ventilation is needed, and firefighter must evaluate all pertinent safety
issues and avoid unnecessary risks. So, when working on a roof, firefighters should have to
safe exit routes so that in case of problem at one roof, you can go for another one. Vertical
ventilation allows the product of combustion travel up and out.

So, in this particular module we have discussed different aspect of electrostatic electricity, dip
piping, relaxation, ventilation aspect, etc.

(Refer Slide Time: 31:14)

Again, you can have a look for further reading of these references, thank you very much.