International Journal of Mechanical Engineering and Technology (IJMET) Volume 9, Issue 10, October 2018, pp. 1336–1345, Article ID: IJMET_09_10_137 Available online at http://iaeme.com/Home/issue/IJMET?Volume=9&Issue=10 ISSN Print: 0976-6340 and ISSN Online: 0976-6359
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FIRE SAFETY ASSESSMENT IN MANUFACTURING OF FIREWORKS PRODUCTS
M. Anandhan and Dr. T. Prabaharan Department of Mechanical Engineering Mepco Schlenk Engineering College, Sivakasi, Tamilnadu
M. Muhaidheen Department of Electrical and Electronics Engineering, Mepco Schlenk Engineering College, Sivakasi, Tamilnadu, India
S. Balamurugan PG Scholar, Mepco Schlenk Engineering College, Sivak si, Tamilnadu
ABSTRACT Fireworks industry is one of the leading employment providers to thousands of people especially in the southern parts of TamilNadu in India.The firework units uses various flammable chemicals such as Sulphur, Gun powder mixture, Aluminium powder, Potassium Nitrate, Barium nitrate, Strontium nitrate, Charcoal etc. which are prone for fire and explosion due to their inherent property. Thus fire safety assessment of these units is a prime importance in the fireworks units. In this reported work fire safety assessment and fire and explosion index for select storage and process rooms for a typical fireworks unit were carried out.Fire safe assessment was carried out based on the guidelines from National building code of India 2016, explosives rules 2008 and other international standards and codes including National fire protection Association (NFPA).The fire load and fire densities were estimated for various process rooms of the fireworks unit.The fire load calculation helps to categorize the building as low or high fire hazard. Based on the estimation of Fire & Explosion Index value chemical storage rooms found to have intermediate fire hazard. Keywords: Fireworks, Safety assessment, Fire & Explosion Index, and National building code of India. Cite this Article: M. Anandhan, Dr.T. Prabaharan, M. Muhaidheen and S. Balamurugan, Fire Safety Assessment in Manufacturing of Fireworks Products, International Journal of Mechanical Engineering and Technology, 9(10), 2018, pp. 1336–1345. http://iaeme.com/Home/issue/IJMET?Volume=9&Issue=10
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1. INTRODUCTION A hazard identification technique seeks to identify hazards in the workplace, as well assess the risks associated with the identified hazards. The aim of conducting hazard identification technique is to prevent and reduce any adverse impact that could result in injuries to workers, or damage to property and the environment. This was done through a review of records of accidents and injuries, a site inspection, work observation, and other methods of collecting data on a particular work environment. The important element of Hazard evaluation in fireworks unit is fire safety assessment. For the assessment of safety the process details, chemicals used, activities carried out in the units and the layout drawings are used. The aim of a fire risk/ safety assessment is to identify the hazards and to reduce the risk of those hazards and to decide fire precautions and escape routes which are necessary to ensure the safety of people in the fireworks unit if a fire does start. N.D. Hansen et al provided a guideline for fire risk assessment of residential high rise buildings and have developed the fire risk model to evaluate risk level to the occupants and property damage based on building characteristics. A fire risk assessment is an organized and methodical examination in industries and buildings to identify the likelihood of a fire starting. E. Zio et al, provided a comprehensive review on the future risk assessment and challenges ahead for risk assessment for new technologies and new systems.Cong zhang et al, stressed the need for mature and perfect fire safety assessment and analysed the fire safety system on storage enterprises of dangerous chemicals and established the fire risk inspection model to improve fire safety in chemical warehouse.The hazard assessment for the storage, manufacturing and handling of flash compositions was conducted by Sivapirakasam et al, and highlights the necessary safety precautions which are required to be followed in the manufacture of flash compositions. Vignes et al, as conducted the study on risk assessment of the ignitability and explosivity of aluminium Nano powders and investigated fire protection measures by suggesting various types of barriers in the case study considered. N. Rajathilagam et al conducted a study on accident trend in fireworks industry for the past decade in sivakasi, which aimed at studying the status of the working environment, different type of workers in the fireworks industry and most importantly the causes of accidents and preventive measures taken by the fireworks units. Jafee suardin et al, provides a systematic procedure for incorporating safety into the conceptual process design to achieve inherently safer design of the process. The proposed procedure is applied to a case study involving reaction and separationand demonstrated the incorporation of Fire and explosion index to design process. Jai P. Gupta et al, 2003reported that Dow Fire and Explosion Index is universally used in evaluating the process hazard and suggested to incorporate the loss control measures LCMs in the current procedure of F&EI calculation.N.jensen et al, proposes a new improved estimation of the damage factor used in the Dow fire and explosion index.Ji wang et al, proposedthemodified F&EI using classified safety measures and the inclusion of the credit factors for process protection measures and established the maximum property damage incorporating loss reduction measures. Azhagurajan et al, 2014studied the positive and negative impact of using nano powder in the manufacturing of fireworks products. G.V. Hadjisophocleous and Z. Fu provided a review of various work in the area of fire risk assessment and various risk assessment models available and methodologies used in various countries. Niresh Behari et al proposed fast and
http://iaeme.com/Home/journal/IJMET 1337 [email protected] M. Anandhan, Dr.T. Prabaharan, M. Muhaidheen and S. Balamurugan economical approach to assess impact of fires, explosions and toxicity for LPG gas storage and studied the explosion and toxic effects of hydrocarbons stored in a sphere and bullet. Jing Xin et al,presents building fire risk analysis model based on scenario clusters and its application in fire risk management of buildings. Also Fire & Explosion Index was estimated to assess the severity in case of fire.The Fire & Explosion Index is a tool used for the assessment of relative hazards of different process units. The index provides a standard approach for assessment of hazards. The fireworks unit was visited, thoroughly studied and a comprehensive checking for the adherence to the safety guidelines was done[21-30].
2. METHOD
2.1. Hazard identification checklist The hazard identification checklist was developed by using the national building code of India 2016 and explosive rules 2008. Hazard identification is then carried out using the checklist as a guideline by collecting the process data in the industry and existing procedures followed for manufacturing fireworks products.
2.2. Layout of the factory The general layout followed by fireworks units is shown in fig 1. The main processes involved in the industry areweighing , Gun powder and White powder mixing and Filling, Manufacturing of crackers, Drying of products, Fuse wrapping and cutting, and Packing of explosives. The hazard identification checklist is used to understand the conditions exist in the industry and was developed by referring standards. The checklist is made from the important parameters mentioned for the group J hazardous building category of national building code. The findings shows that the condition mentioned are mostly followed in the units. The mounds and safe distance between the sheds mentioned in the checklist are the important factors for fire risk assessment.
3. FIRE LOAD CALCULATION
3.1. Fire load calculation formula Fire load is defined as the heat energy that could be released per square meter of floor area of a shed by the complete combustion of the chemicals and paper in the shed. The fire load [20] is given by
Where
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Figure 1 shows General layout of the fireworks unit. No 1 to 41— Filling, mixing, manufacturing and packing rooms. No 45 to 47— drying platform No 50—Fuse cutting rooms No 48 to 49—Storage rooms mound or blast walls The table 1 shows the sample hazard identification checklist for fireworks industry based on national building code of India and explosive rules 2008.
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Table 1 the sample hazard identification checklist for fireworks industry based on national building code of India and explosive rules 2008 Conditions specified in codes and explosive Sl. No Yes/no Remarks rules Height of the building or shed not more than The condition existing in the industry 1 Yes 15m of the shed is 3.60m The capacity of magazine to exit should be The existing condition of magazine exit 2 Yes having a width of 0.25m capacity is 0.2m All the doors open outwards in the 3 Exit door must open outwards Yes industry. Handling of chemical powders such as Restriction on handling explosives 4 Yes mixing and filling is carried out before At the time of sunset and sunrise noon only. 5 Restriction on smoking inside the factory Yes Strongly prohibited Lightning arrester Is provided in the 6 Protection from lightning Yes magazine and in the factory. Precautions against danger from water near to No water source available near to the 7 Yes the storage of chemicals storage of chemicals. 8 Provision of mounds Yes Mound walls existing in the industry 9 Magazine should be at the ground level Yes Magazine existing at the ground level 10 Storage of compatible explosives Yes Stored in separate place Safe distance is followed for each shed 11 Safety distance between sheds should be 12m Yes and is 12m Surface should be Rubber mat with 5mm thickness is 12 Yes Made by antistatic rubber mat. provided. Only 5kg is allowed to work in the mixing The condition is followed in the 13 Yes and filling room industry 14 Door height should not exceed to 2m Yes The doorheight maintained at 2m. The following table shows the quantity of chemicals stored in various process and storage rooms of fireworks industry and area of the rooms.
Table 2 quantity of chemicals stored in various process and storage rooms of fireworks industry and area of the rooms ROOM AREA STORAGE OF SI NO TYPE OF ROOM m2 POWDERS IN Kg 1 Gun powder room 9 5 2 Sulphur storage room 6.48 200 3 Charcoal storage room 5.76 200 4 Fuse making room 12.6 2.5
3.2. Calorific values The table 3 provides the calorific values used in the fire load calculation.
Table 3 the calorific values used in the fire load calculation Calorific value SI.no Name of the chemical MJ/Kg 1 Gun powder 3MJ/Kg[14] 2 Sulphur 9.16 MJ/Kg[14] 3 Charcoal 29 MJ/Kg [14] 4 Cardboard paper 15.38 MJ/Kg [1] 5 Wood 18.6 MJ/Kg [1]
3.3. Fire load calculations The following calculations were done based on the calorific value of the chemicals. The area and weight of the rooms are taken from Table 2.
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3.3.1. Fire load calculation for gun powder preparation room considering only the chemical stored.
3.3.2. Fire load calculation for storage room Sulphurconsidering only the chemical stored.
3.3.3. Fire load calculation for storage room Charcoalconsidering only the chemical stored.
3.3.4. Fire load calculation for fuse making room
3.4. Summary of the fire load calculations Fire load densities were calculated using calorific value collected from literature. The mass of the combustible materials is calculated based on the usage of chemicals and allowable limit of materials as per explosive rules 2008. The high energy content is identified in charcoal storage room and sulphur storage room.The table 4 shows thefire load densities of various rooms.The hazard can be reduced by using the lesser quantities of chemicals in the storage rooms. According to the national building code rooms with the high fire hazard due to high fire load density can be installed with the sprinkler and fire alarms. But in the fireworks industry fire load can be reduced by using still lesser amounts of chemicals in storage rooms and handling rooms. Thus the fire load is a useful information to know about hazardous nature of storage and process rooms in fireworks manufacturing unit.The fire load densities of various rooms are provided in the table 4.
Table 4 Fire load densities of various rooms STORAGE OF FIRE LOAD ROOM SI NO TYPE OF ROOM POWDERS IN DENSITY IN AREA Kg MJ/m2 1 Gun powder room 9 5 1.667 2 Sulphur storage room 6.48 200 282.71 3 Charcoal storage room 5.76 200 1006.94 4 Fuse making room 12.6 2.5 12.85
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4. ESTIMATION OF THE FIRE AND EXPLOSION INDEX The Fire and Explosion Index is a tool to determine the areas of greatest loss potential in a particular process.
4.1. Material factor The material factor choosen from NFPA 704 (15) based on the flammability ranking of combustible powders. The material factor choosen for gun powder and sulphur are 29 and 24 respectively.
4.2. Calculation of fire explosion index The fire and explosion indices were calculated for storage room of sulphur and gun powder preparation room.
4.2.1. Fire explosion index for Sulphur storage room First the material factor is obtained from NFPA 704.For general process hazards (F1) the penalty factor were chosen based on the industrial data and range provided. The material handling and transfer chosen are 1.0 and 0.6 respectively. The general process hazard F1 is calculated by adding all the penalty factors. Similarly for specific process hazards penalty factors were selected from the range. Finally the fire and explosion index was estimated using general process hazard, specific process hazard and material factor. The table 5 shows the calculation of fire and explosion index for the sulphur storage room.
Table 5 Fire & explosion index table for sulphur storage room PROCESS UNIT: STORAGE ROOM BASIC MATERIAL FOR MATERIAL FACTOR: SULPHUR MATERIAL FACTOR FROM THE TABLE COMBUSTIBLE POWDER (4) 24 PENALTY FACTOR PENALTY FACTOR 1 GENERAL PROCESS HAZARDS RANGE USED BASE FACTOR………………………… 1.00 1.00 A.EXOTHERMIC CHEMICAL REACTIONS 0.30 to 1.25 B.ENDOTHERMIC REACTIONS 0.20 to 0.40 C.MATERIAL HANDLING AND TRANSFER 0.25 to 1.05 1.00 D.ENCLOSED OR INDOOR PROCESS UNITS 0.25 to 0.90 0.60 E.ACESS 0.20 to 0.35 G.DRAINAGE AND SPILL CONTROL 0.25 to 0.50 GENERAL PROCESS HAZARDS (F1) 2.6 PENALTY FACTOR PENALTY FACTOR 2 SPECIAL PROCESS HAZARDS RANGE USED BASE FACTOR 1.00 1.00 A TOXIC MATERIALS 0.20 to 0.80 B SUB-ATMOSPHERIC PRESSURE(<500G) 0.50 C ALWAYS IN FLAMMABLE RANGE 0.80 0.80 D DUST EXPLOSION 0.25 to 0.20 E LOW TEMPERATURE 0.20 to 0.30 F CORROSION AND EROSION 0.10 to 0.75 G LEAKAGE JOINTS AND BREAKAGE 0.10 to 1.50 H HEAT OIL EXCHANGE SYSTEM 0.15 to 0.15 I ROTATING EQUIPMENT 0.50 SPECIAL HAZARDS FACTOR (F2) 1.80 PROCESS UNIT HAZARD FACTOR F1×F2 (F3) 4.68 FIRE AND EXPLOSION INDEX F3×MF= F&EI 112.32
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4.2.2. Fire explosion index for gun powder storage room The table 6 shows the calculation of fire and explosion index for the gun powder storage room.
Table 6 Fire & explosion index table for storage room PROCESS UNIT: GUN POWDER STORAGE ROOM BASIC MATERIAL FOR MATERIAL FACTOR: GUN POWDER MATERIAL FACTOR FROM THE TABLE COMBUSTIBLE POWDER (4) 29 PENALTY FACTOR PENALTY FACTOR 1 GENERAL PROCESS HAZARDS RANGE USED BASE FACTOR………………………… 1.00 1.00 A.EXOTHERMIC CHEMICAL REACTIONS 0.30 to 1.25 0.50 B.ENDOTHERMIC REACTIONS 0.20 to 0.40 C.MATERIAL HANDLING AND TRANSFER 0.25 to 1.05 0.25 D.ENCLOSED OR INDOOR PROCESS UNITS 0.25 to 0.90 E.ACESS 0.20 to 0.35 G.DRAINAGE AND SPILL CONTROL 0.25 to 0.50 GENERAL PROCESS HAZARDS (F1) 1.75 PENALTY FACTOR PENALTY FACTOR 2 SPECIAL PROCESS HAZARDS RANGE USED BASE FACTOR 1.00 1.00 A TOXIC MATERIALS 0.20 to 0.80 B SUB-ATMOSPHERIC PRESSURE(<500G) 0.50 C ALWAYS IN FLAMMABLE RANGE 0.80 0.80 D DUST EXPLOSION 0.25 to 0.20 E LOW TEMPERATURE 0.20 to 0.30 F CORROSION AND EROSION 0.10 to 0.75 G LEAKAGE JOINTS AND BREAKAGE 0.10 to 1.50 H HEAT OIL EXCHANGE SYSTEM 0.15 to 0.15 I ROTATING EQUIPMENT 0.50 SPECIAL HAZARDS FACTOR (F2) 1.80 PROCESS UNIT HAZARD FACTOR F1×F2 (F3) 3.15 FIRE AND EXPLOSION INDEX F3×MF= F&EI 91.35
5. RESULTS AND DISCUSSIONS The hazard identification technique is useful for providing the control measures against the existing hazards. The fire load density was calculated for sulphur, charcoal, gun powder manufacturing room and Fuse making room. Calculation is done based on calorific value of chemical and area of the room. The charcoal and sulphur storage rooms are found to have significant fire loads compared to fuse making and gin powder manufacturing room.. The fire load was compared from fire grading of buildings [16]. As per the IS standard the fire load density less than 275000 kcal/m2are considered as low fire load. It was found that the calculated fire load values are less than the 275000 kcal/m2 and thus the select storage rooms have low fire load rooms contrary to the general notion of high fire loads in pyrotechnic units. This is due the restriction of quantity of chemicals imposed by explosive rules 2008 such as 5 kg of chemical in mixing room Calculation of Fire and explosion indices for gun powder mixing room and sulphur storage room were also carried out using the standard methodology. The degree of hazard is found to be moderate in gun powder storage room and slightly intermediate in the sulphur storage room.
6. CONCLUSION The fire load and fire explosion indices were calculated to check the severity of fire hazard in select storage rooms of fireworks industry. Fire safety assessment using the checklist also carried out.
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1. The fire load was calculated to identify the maximum energy that will be released during fire in the shed area. The fire load is significant at charcoal storage room which is 1006.4 MJ/m2 and sulphur storage room is 282.71 MJ/m2 compared to the other rooms. 2. The fire load calculation can be used to suggest fire control measures. 3. The fire explosion index was calculated to identify the degree of fire hazard in the gun powder storage room and sulphur storage room. F&EI for sulphur storage room is 112.92 and for gun powder is 91.35.The above values indicates that above storage rooms are having the intermediate hazard. Similar calculations can also be carried out for more risky process rooms such as flash powder making room, Magazine room, packing sheds and manufacturing rooms. Fireworks industry uses hazardous chemicals which are prone for fire and explosion. Thus it is very much essential to carryout the fire safety assessment by checking the compliance of fire safety codes, fire load calculations and estimation of Fire and explosion indices.
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