By Craig Voelkert
Amerex Corporation
Editor’s Note – This article, in part, appeared in the February 2006 issue of Occupational Health and Safety magazine.
Just five years ago, in 2001, the fire incident log for industrial facilities in North America looked like this:
• March 1 – Iron Range, MN: Fire destroyed a cabinet plant that was the community’s second-largest employer.
• March 2 – Calgary, AB, Canada: A worker leaped to safety with his clothes aflame after an explosion at a wood processing plant.
• March 3 – Greensboro, NC: An unused room at a packing plant was damaged by fire.
• March 3 – Evans City, PA: High winds fanned a massive fire that destroyed the production building at a steel plant. Fifteen fire companies battled the blaze for two hours.
• March 6 – Casper, WY: A fire broke out at a tear gas manufacturing plant with four employees exposed to the gas.
These tragic stories – all within one week’s time – illustrate the frequency of just one of the many hazards in industrial workplace settings that are associated with the use of electrically powered equipment and can have a dramatic affect on workers and other staff. Some of these potential hazards include: interference with equipment; accidental contact with a worker or other individual resulting in burns or serious eye or bodily injury; explosions; and fires.
More than 17,000 fires occur in industrial settings such as manufacturing plants each year resulting in huge property losses and loss of revenue. The reality is that the presence of a heat source combined with manufacturing equipment, chemicals, combustibles, and the likely presence of flammable vapors in direct proximity to workers and others presents a particularly significant level of potential risk. In seconds, a life-threatening situation can arise with little or no time to react. For these reasons, fire prevention efforts must receive primary consideration, followed by effective response procedures in the event of unanticipated incidents.
Choosing the Proper Extinguisher
When selecting a fire extinguisher, consideration must be given to the effect each form of extinguisher discharge will have on controlling the fire, the products being manufactured at hand, and the operating environment. For example, dry chemical extinguishers are effective but produce a large amount of residue that could contaminate a large amount of food or feed products within a processing plant. Carbon dioxide (CO2) and other clean agent extinguishers do not produce a residue but can cause respiratory complications for workers involved. They also have little or no rating to extinguish class A fires (ordinary combustibles).
A new water mist extinguisher shows promise for use in many industrial environments. This extinguisher possesses a class A and class C rating, making it suitable for use on ordinary combustibles and fires involving energized electrical equipment. The fine spray from the unique misting nozzle provides safety from electrical shock, enhances cooling and soaking characteristics of the agent, and reduces scattering of the burning materials. The de-ionized water agent is non-toxic, leaves no powder residue, and is not a respiratory threat. The unit is also easy to clean because it is covered with an antiseptic white paint finish.
Some manufacturing facilities have a problem with lint or dust fires that may occur within the ductwork, on filter faces, or behind processing machines themselves. A strict regimen of prevention involving equipment maintenance and cleaning of filters, ductwork, and equipment will help to keep such fires from occurring.
These types of fires can become “deep-seated” very quickly, and the use of a violent discharge extinguisher can spread the burning material around. By choosing a more specialized extinguisher to protect this hazard, such as a water mist fire extinguisher, chances of spreading the fire are minimized, better penetration can be achieved, the wand helps access tight spaces, and less damage occurs during extinguishing.
While traditional agents, such as ABC dry chemical, are certainly effective on electronic fires occurring in manufacturing facilities, other alternatives in fire extinguisher choice may serve the same purpose while requiring less cleanup after the incident. Plant managers and production designers should review their processes and ask questions involving different likely fire scenarios when making choices regarding the type of first response equipment they will have available for these specific hazards.
If a soft, controlled discharge of the agent is required in order to confine the damage to a specific, localized area, either CO2 extinguishers or water mist extinguishers may be more appropriate. If the manufacturing cannot tolerate water of any type, then alternative “clean” agents, such as halon alternatives, may be a more viable choice.
Many large manufacturers have placed pressurized water extinguishers that employ tap water and a straight stream next to a CO2 extinguisher, the concept being that the water extinguisher will be used exclusively for class A (normal combustible) fires and the CO2 would be used for class C (live electrical equipment) fires. With the advent of the water mist extinguisher, many of the traditional water extinguishers using a straight stream are replaced in these situations with the water mist extinguisher, affording an extra margin of safety for both the employees and the manufacturing process equipment.
In food and feed processing environments, cleanup can be critical, and limiting contamination can be as much of a concern as the fire itself. Production designers and supervisory personnel should plan for likely fire scenarios and make selection of first response equipment based on limiting damage and downtime before, during, and after an incident.
Sanitation concerns are also important in this envi-ronment. Extinguisher selection should include equipment that is easy to keep clean. With recent concerns involving food and feed safety, it is important that plant personnel check with extinguisher manufacturers regarding the appropriate equipment to use and the proper materials used to clean the equipment. Some cleaning solutions may attack different materials, resulting in premature damage and replacement of first response devices.
Care also should be taken to ensure the extinguishing agent being used will remain within the immediate area of the fire and will not affect food and feed products in adjacent areas. A soft discharge pattern may be of greater use in this situation, and the use of traditional agents, such as ABC dry chemical, will be effective on the fire. However, they may cause problems with cleanup and destruction of product after the incident.
Select and install appropriate emergency response equipment in all work areas. This should include one or more fire extinguishers of a suitable type in each room and area of the plant or facility. These extinguishers must be installed so the employees have unobstructed access during an emergency. Train personnel in accordance with the operating guidelines of the extinguisher.
Achieving Balanced Fire Protection
To ensure quick response to fire, business, building owners, and workers need to be certain that a complete and balanced approach to fire protection exists in their workplace to provide occupants and others with the tools to defend in place against a fire, once the fire department has been called and everyone is safe.
A balanced fire protection plan is made up of several components. These life safety devices include fire extinguishers, standpipe fire hose stations, smoke/fire alarms, exit signs and emergency lighting, and sprinkler and fire suppression systems. All these components must be in place and well maintained to make a difference in case of fire.
Fire protection equipment is legislated by city, state, and federal laws, many of them directly adopted or adapted from model code-making organizations, such as the International Code Council and the National Fire Protection Association. Building owners must comply with the fire codes of their area; however, considering the history of fires and the potential severity of future ones, building owners may want to evaluate their balanced fire protection plan and exceed the requirements of local codes for added protection. Businesses, too, should become advocates for their employees’ safety by urging building owners to go above and beyond local requirements for extra precautionary measures. A balanced fire protection plan is the first line of defense against fire. Small fires in the beginning stage can be suppressed with portable fire extinguishers or water hose lines connected to building standpipes. Even if the occupants are unable to extinguish the fire, they are able to gain time and protect the exit way in order to evacuate or defend in place, while waiting for the fire department to respond.
Here are some facts to consider. When fires are extinguished in the early stages:
• Ninety-three percent of all fire-related deaths occur once the fire has progressed beyond the early stages.
• Ninety-five percent of all direct property damage occurs once the fire has progressed beyond the early stages.
Conclusion
The fire probability of a manufacturing facility can be common, and the level of injury to workers and others involved in such a fire can be catastrophic. This article has outlined a range of resources that offer guidance in this area, as well as pertinent safety practices.
Lastly, reinforce the importance of prevention, prevention, prevention to all workers on a continuous basis, but be ready to respond to the unexpected event. v
Craig Voelkert has more than 34 years of fire equipment experience and has extensive experience as a field instructor at the Fire Protection Training Academy in the areas of fire protection and suppression techniques.
October 2006 Render