Essential Guide to Industrial Fire Safety

Causes of Industrial Fires and Explosions

Fires pose a significant threat, making prevention essential for protecting lives, preventing injuries, and safeguarding property. The National Fire Protection Association (NFPA) estimates that approximately 36,784 fires occur annually at industrial or manufacturing properties, causing direct property damages totaling $1.5 billion.

Fire safety is a major concern for industrial facilities due to the high likelihood of fires and explosions, which can be caused by a variety of factors, including:

• Combustible Dust: The Occupational Safety and Health Administration (OSHA) defined combustible dust as a solid material composed of particles that can present a fire or explosion hazard when combined with oxygen and an ignition source.
• Hot Work: Hot work involves any activity that generates heat, sparks, or flames, such as welding, grinding, and cutting. Without adequate safety precautions, these activities can ignite nearby flammable materials.
• Flammable Products: Industrial settings often store or use flammable products, such as chemicals, oils, and gases. If not stored properly or handled carefully, these materials can cause fires and explosions.
• Faulty Equipment and Machinery: Poorly maintained or malfunctioning equipment and machinery can create sparks, overheating, and other ignition sources that can lead to fires.
• Electrical Hazards: Overloaded circuits, exposed wires, and damaged electrical equipment are common causes of electrical fires, especially in older facilities with outdated wiring.
• Human Error: Human error or negligence often causes fires and explosions. Examples include improper storage of hazardous materials, failure to follow safety protocols, or incorrect use of equipment.

Standards and Regulations

Industrial fire safety is heavily regulated to ensure the highest level of protection for workers and property. Fire safety regulations and guidelines vary per country, and some of the most common ones include:

United States

• OSHA standards: The OSHA 29 CFR 1910 (General Industry) has specific regulations for fire safety in industrial settings, including requirements for emergency action plans, fire prevention plans, and hazardous material storage.
• NFPA standards: The NFPA has published over 300 fire protection codes and standards. One example is NFPA 660, which sets universal standards for handling combustible dust in all relevant facilities and worksites.
• Environmental Protection Agency (EPA): The EPA regulates hazardous waste and materials that pose a fire risk, including the Resource Conservation and Recovery Act, for proper storage, transportation, and disposal of hazardous materials.
• American Petroleum Institute (API) standards: The API creates standards for the safe production, transportation, and storage of petroleum products and hazardous materials.

United Kingdom

• Regulatory Reform (Fire Safety) Order 2005: This is England and Wales’s primary fire safety legislation. It places the responsibility for fire safety on a designated ‘responsible person,’ usually the employer or building owner.
• Health and Safety at Work Act 1974: While not specific to fire safety, this act sets out general duties for employers to ensure the health and safety of employees and others affected by their work activities, including fire safety measures.
• BS 5839 (Fire detection and alarm systems): This British Standard offers guidance on planning, designing, installing, commissioning, and maintaining fire detection and alarm systems in and around buildings.
• BS EN 3 (Portable fire extinguishers): This standard specifies requirements for portable fire extinguishers. It covers aspects such as fire ratings, performance, and testing requirements.

Australia

• Work Health and Safety Act 2011: Australia’s primary workplace health and safety legislation outlines the general duties of care for employers, including provisions related to fire safety in the workplace.
• Building Code of Australia (BCA): Part of the National Construction Code, the BCA sets out the minimum requirements for the design and construction of new buildings and new building work in existing buildings. It includes specific provisions for fire safety in buildings.
• AS 1851 (Routine service of fire protection systems and equipment): This standard specifies the minimum requirements for the routine servicing of fire protection systems and equipment. It covers inspection, testing, preventive maintenance, and survey procedures.
• AS 3745 (Planning for emergencies in facilities): This standard provides guidelines for developing, implementing, and testing emergency plans in facilities. It includes provisions for fire emergencies.

European Union

• EU Directive 89/391/EEC (Safety and health of workers): This directive, also known as the OSH “Framework Directive,” sets out general principles for managing occupational safety and health, including fire safety.
• EN 54 series (Fire detection and fire alarm systems): This series of European standards specifies requirements and test methods for fire detection and fire alarm system components. Different parts of EN 54 cover various elements, such as control and indicating equipment, heat detectors, and smoke detectors.
• EN 3 (Portable fire extinguishers): Similar to the British standard, this European norm specifies requirements for portable fire extinguishers, including performance, durability, and safety aspects.
• Seveso III Directive (2012/18/EU): This directive aims to prevent major accidents involving dangerous substances and reduce their impact on human health and the environment. It applies to thousands of industrial sites, mainly in the chemical and petrochemical sectors, where these substances are used or stored in large quantities.

How to Prevent Fires and Explosions in Manufacturing Plants

Preventing fires and explosions should be a top priority for industrial facilities. Here are some essential steps that can help prevent these incidents from occurring:

• Design a Fire Protection System According to NFPA Standards: The NFPA has published various codes and standards that guide fire prevention, protection, and suppression in industrial settings. Adhering to these standards can significantly reduce the risk of fires and explosions.
• Conduct a Dust Hazard Analysis (DHA): A DHA is a tool for identifying combustible dust hazards in a facility and determining proper control measures. The NFPA 660 standard requires all facilities that handle combustible dust to conduct a DHA.

• Consider Special Hazard Fire Systems for Heavy Machinery: Certain types of machinery, such as oil-cooled transformers and hydraulic systems, can pose unique fire risks. Special hazard fire systems, designed specifically for these hazards, can help prevent fires from occurring.
• Regularly Inspect and Maintain Equipment: Regular inspections and maintenance of equipment are crucial in preventing fires and explosions. It includes checking for any wear and tear or malfunctions that could lead to a fire.
• Provide Proper Training to Employees: Educating employees about fire safety and hazards and how to prevent them can significantly reduce the risk of fires and explosions.
• Implement Hazardous Material Storage and Handling Measures: Flammable liquids, gases, and chemicals should be stored in designated areas that are well-ventilated and away from potential ignition sources.
• Regularly Test Fire Protection Systems: Regularly test your fire protection systems to ensure they work properly and meet the NFPA standards.
• Ensure Emergency Plans are in Place: An emergency evacuation plan can save lives during a fire or explosion. This plan should include evacuation routes, designated meeting points, and procedures for notifying emergency services.