Fire Protection System :

Mechanical & Chemical explosion,

Multiphase reactions.
Fire prevention & types of fire extinguishers.
Critical hazard management system.

By: Vrushabh Khaunte

Roll No: 08 MPharm (PQA) Sem-II
Hazards And Safety Management

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 Introduction
An explosion is a rapid increase in volume and release of energy to its
extreme, usually with the generation of high temperatures and release of
gases.

There are three fundamental types :

1. Mechanical energy
2. Chemical energy
3. Nuclear energy

A Nuclear explosion is nothing but explosion that occurs as a result of

rapid release of energy from a high speed nuclear reaction.

A mechanical explosives refers to the one that depends on a physical

reaction, ex. overloading a container with compressed air. 2
 Chemical explosives are of two types :
1. Detonating or high explosives and
2. Deflagrating or low explosives

Detonating explosives such as Trinitrotoluene (TNT) and Dynamite, are

characterized by extremely rapid decomposition and development of
high pressure.

Deflagrating explosives, such as black and smokeless powders, involve

merely fast burning and produce relatively low pressures.

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 Mechanical Explosion
Mechanical Explosions are those in which high pressure gas produces a physical
reaction, vessel failure or rupture of the container.

The bursting of a sealed or partially sealed container under internal pressure is

often referred to as “Mechanical Explosion”.

Material that is stored in the container, is flammable, then in many instances a

resultant fire occurs as long as there is an ignition source or the temperature of the
product is above its autogenous ignition temperature.

Its example includes an overheated boiler or a simple tin can of beans tossed in fire.
Boiling Liquid Expanding Vapor Explosions (BLEVE) are one type of mechanical
explosion.
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Exs. -
West Pharmaceutical Services explosion (2003) - Dust explosion caused
fire and injuries. (fine powders when mix with air can create explosive
concentrates. FBD, Milling, etc. increases its risk).

Escientia Pharma Factory Blast, Andhra Pradesh (2024) - Blast happend

when worker tried to stop leak of solvent Methyl-tert-butyl ether
(MTBE).

Thane, Maharastra. Multiple Boiler Explosion - Over heated boilers or

pressurised vessels ruptured leading to explosion.

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 Chemical Explosion
A chemical explosive is a compound or mixture which , upon the application of
heat or shock, decomposes or rearranges with extreme rapidity, yielding
energy in form of heat and gases .

For a chemical to be explosive, it must exhibit all of the following :

1. Rapid expansion (i.e. rapid production of gases or rapid heating of
surroundings.)
2. Evolution of heat
3. Rapidity of reaction
4. Initiation of reaction.

Chemical explosions( both accidental and intentional)are often initiated by an

electric spark or flame. 7
Combination reactions require that two or more components react together
exothermically to produce hot gases.
Ex- Ammonium nitrate and fuel oil (ANFO), Gunpowder (Potassium nitrate +
Carbon + Sulfur).
The reactants that make up the explosive must be carefully mixed to assure that
the reaction will continue.
The damage caused by an explosion partly depends on, how fast the explosive
reaction occurs.
Decomposition reactions occurs much faster than Combination reactions.
They are more likely to be used for military applications because they are more
destructive.
They also have a stronger shattering effect ( called brisance) than combination
reactions.
Combination explosions are frequently used in mining operations because they
have lower brisance and occur at slower rates.
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 Multi-phase Reactions :
Multiphase reactions refer to reactions involving components in different phases,
and is a combination of simultaneous phase change and conversion of some
materials into others.

Classification based on number of phases :

Gas-Solid Catalytic - (hydrogenation of benzene to cyclobenzene)
Gas-Liquid - (absorption of CO₂ into aq. alkanolamine sol.)
Gas-Liquid with Solid reacting - (Commonly used for slurry reactors, Fluidized beds)
Gas-Liquid-Liquid-Solid
Gas-Solid Non Catalytic
Gas-Liquid Solid Catalytic
Liquid-Liquid
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 Hydrogenation – key step in many chemical reactions.
Carbonylation – used in synthesis of Ibuprofen and Penicillin-G intermediates.
Asymmetric hydrogenation – Used for synthesis of S-Naproxen.

Benefits :
Process intensification – Improving rate of reactions..
Efficiency – mass transfer

Versatility.. - Hydrogenation, Oxidation, different Phase Transfer Catalytic reactions

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 Transport effects :
Dangerous goods can be transported without causing unnecessary hazards if
handled properly and with care.

United Nations statistics show that, half of all the goods transported belong to the
category of dangerous goods.

Petroleum products transported by tankers form a large quantity of transported

goods, but road and railway transport is also significant.
Ex. - 85% of chlorine, which is one of the very dangerous chemicals, is
transported by railways.
- Certain medications are light sensitive and can degrade when exposed to
excessive light.

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Even frequent waste from ships,household,cars or agriculture increase the load
on the environment.
Ex.- 1 litre of oil-can under non favorable circumstances, spoil a million liters of
drinking water.
A spill of hydraulic acid from a truck can lead to environmental damages.

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 Dangerous situations :
There is always a risk of spillage during the transport of hazardous goods.
When incompatible substances mix with each other there is a possibility of a
chemical reaction, which can cause enough heat to cause a fire and can release
dangerous gases.
Ex. - Toxic Nitrous Oxides (N₂O) are formed when Ammonium Nitrate(NH₄NO₃) (in
fertilizers) decomposes in a fire.
- Toxic gases which fume off, during a spillage of conc. Sulphuric acid (H₂SO₄) which
is absorbed in sawdust.
Special conditions can increase the risk – A chemical substance or preparation may
be hazardous in itself when it comes into contact with other chemicals including
air,water or humidity.
Ex. - When calcium carbide ( used in the production of acetylene and pyrotechnics)
comes in to contact with water, it releases the extremely flammable gas acetylene (
used in welding flame) creates an explosion hazard. 14
Fire Classification :
Class A : water type

Class B : foam type/ CO₂

DCP
Class C : CO₂

Class D : DCP(specialized)

Class E : CO₂

Class F/K : Wet chemical

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Types of Extinguishers :

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 Water Fire Extinguisher :

Fire Classification : A

Water mist
Water spray

Fire Extinguisher Suitability :

Water fire extinguishers are suitable for use in
environments containing solid combustible materials
such as wood, paper and textiles.
It is important to remember that water conducts
electricity and should not be used around electrical
equipment.
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Foam Fire Extinguisher :

Fire Classification : A , B

Fire Extinguisher Suitability :

Foam fire extinguishers are ideal for use on fire
involving solid combustible materials and are highly
effective on flammable liquid fires.

The layer of foam applied by these extinguishers helps

to prevent re-ignition after the fire has been
extinguished.

Involves smothering a fire.

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ABC Dry Powder Fire Extinguisher

Fire Classification : A , B , C , E

Standard
Specialized

Fire Extinguisher Suitability :

Powder fire extinguishers are ideal for use in mixed risk
environments and offer excellent all round fire protection.

With a unique class C rating, powder fire extinguishers are

best suited for solution for fires involving flammable gases.

Sodium bicarbonate or Monoammonium phosphate used

to create barrier between fuel and oxygen.
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Carbon Dioxide Fire Extinguisher :

Fire Classification : B , E

Fire Extinguisher Suitability :

CO₂ fire extinguishers are suitable for use on flammable

liquid fires and are extremely effective at extinguishing
fire involving electrical equipment.

CO₂ is also one of the cleanest extinguisher agents and

leaves no residue behind.
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Wet Chemical Fire Extinguisher :

Fire Classification : A , F

Fire Extinguisher Suitability :

Wet chemical fire extinguishers have a unique class F
rating and are usually supplied with a special lance
applicator.

The perfect solution for tackling large burning oil fires,

wet chemical extinguishers are ideally suited to the kitchen
environment.

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Fire Prevention

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 A fire needs three elements - heat, oxygen and fuel.

Without heat, oxygen and fuel a fire will not start or spread.

A key strategy to prevent fire is to remove one or more of heat, oxygen or fuel.
1. Cooling
2. Smothering
3. Starvation
The risk assessment should include detail on all three elements to minimize the
risk of a fire starting/ spreading.

A fire prevention strategy and a fire risk assessment should include detail and a
full consideration of all of the issues - including issues arising from heat, oxygen
and fuel. 23
 Fire Prevention and Prevention of Fire Spread :
1. Control Measures to Minimize the Risk of Fire in a Workplace :

Fire can start only when a source of ignition comes into contact with
some combustible material.
Fire prevention is based on two principles:
Controlling potential sources of ignition.
Controlling combustible materials.
If fire does break out it is important to prevent or minimize its spread.
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The measures that may be taken in the workplace to prevent the outbreak of
fire and control its spread.

General working practices and the structural design of buildings and the use of
particular materials within buildings, which is considered elsewhere.

Central to these measures is the need to recognize the dangers of fire and to
adopt safe working practices.

Fire safety is therefore the responsibility of everyone in the workplace.

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2. Use and Storage of Flammable and Combustible Materials :

To reduce the possibility of fire, careful thought should be given to introduction

of flammable materials into the workplace.

If they can be eliminated or their use limited, then the chances of fire occurring
will be reduced.

If elimination is not possible, then proper management of the flammable

materials is necessary.

All materials which present a risk of fire or explosion must be stored,

transported and used correctly.
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In use and when being handled in any way, flammable and combustible
materials must be treated with great caution.

Staff must be aware of the potential dangers for each type of material and the
conditions under which they may ignite, and should be trained in the correct
procedures to be applied. (Training).

The containers used for flammable materials should be marked.

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3. Control of Ignition Sources :

Most fires in the workplace are caused by a lack of control over sources of
ignition.
These are always preventable by carefully designed working systems and
practices.
Most important practise in recent years - “no smoking” policies.
This was in place for many years in areas, where there is a particular fire risk,
e.g. with flammable materials, but they have now been extended to many other work
and public areas.
If at all smoking is permitted, sufficient metal ashtrays should be provided.

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4. Systems of Work :
Safe systems of work should be specific to the type of work and the equipment used.
(Ex. - Unit operations like blending, granulation, milling and drying can generate
flammable gases/dust that ignite with heat source ). - Proper ventilation required.

5. Working with Hot Processes or Implements :

Most workplaces employ some processes and equipment which by their nature
produce sufficient heat to act as a source of ignition in the right circumstances.
However, good working practices can minimize the risk of fire.
Ex :
1. All appliances and processes which produce heat should be located at a safe
distance away from paper, wood and other combustible materials.
2. Nothing should be placed / stored on heaters. Portable space heaters should be
guarded and placed or fixed to prevent them being knocked over. 29
3. Appliances such as soldering irons or pressing irons should be provided
with stands to prevent them contacting work surfaces and surrounding
materials when not in use.

They should be switched off when not in use.

4. Hot surfaces, such as boilers and associated pipe work, should be lagged (insulate)
to prevent radiant heat becoming a hazard.

5. There should be fire watches during and after hot work.

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6.Machinery :

Poorly maintained machines may overheat & cause sparking - planned

maintenance programme is necessary in order to minimize fire risk.

There should be regular inspections of all machinery and equipment, with checks
on the proper lubrication of bearings and correct tensioning of drive belts to
prevent friction and overheating.

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7. Safe Storage and Use of Flammable Liquids :

When flammable liquids are exposed to the atmosphere they give off flammable and
toxic vapors.

Correct storage and use are therefore essential to prevent accidental ignition or
explosion and they should never be exposed to potential sources of ignition.

Non-flammable substances should be used wherever possible.

When in use in the workplace, the quantity of flammable liquids should be minimized
and contained in a appropriate (like metals) containers with secure lids.

These must be correctly labeled.

The need to decant highly flammable liquids from one container to another should
be kept to minimum, reducing the risk of spillages. 32
 Critical Hazard Management System :
CRITICAL RISK FACTORS :
1. Hydrogen sulfide lowers the LEL(Lower explosive limit) and creates pyrophoric
Iron sulfides .
2. Oil-based work over fluids can absorb oxygen.
3. Mixing chemicals can have unforeseen impacts.
4. High pressures and temperatures can cause auto-ignition.
5. Rapid pressure or temperature changes can trigger explosive events.
6. Pre-existing trapped air can complicate safe operations.

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Fire and Explosion Hazard Management (FEHM) :
Fire and Explosion Hazard Management (FEHM) - means the actions,
procedures and policies used by organizations and individuals to prevent the
occurrence of explosion to unplanned fires and explosion in associated
equipment.

Also applicable to other emergencies, like major spills or toxic releases.

Use of FEHM has now spread to many high-hazard industry sectors, including
chemical storage and protection of critical buildings.

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Hazard Management Steps :

1. Hazard Identification

2. Assessment of Risk How much urgent ?

3. Select and Implement Controls

Eliminate the source
if possible
4. Monitor Effectiveness of Controls

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 Step 1: Identify Hazards :
In consultation with workers identify all potentially hazardous things or
situations that may cause harm.

Generally, hazards are likely to be found in the following:

-Physical work environment,
-Equipment, materials or substances used,
-Work tasks and how they are performed,
-Work design and management.

In order to identify hazards the following are recommended:

(i) Past incidents/accidents are examined to see what happened and whether the
incident/accident could occur again.
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ii) Employees be consulted to find out what they consider are safety issues, i.e. ask
workers about hazards near misses they have encountered as part of their work.
Sometimes a survey can assist workers to provide information about workplace
hazards.

(iii) Work areas to be inspected / examined to find out what is happening now.
Identified hazards should be documented to allow further action. The work
environment, tool and equipment as well as tasks and procedures should be
examined for risks to work health and safety (WHS).

(iv) Information about equipment (e.g. plant, operating instructions) and Material
Safety Data Sheets be reviewed to determine relevant safety precautions.

(v) Welcome creative thinking about what could go wrong takes place, i.e. what
hazardous event could take place here? 39
 Step 2 : Assess Risks
Risk assessment involves considering the possible results of someone being
exposed to a hazard and the likelihood of this occurring.

A risk assessment assists in determining:

- How severe a risk is
- Whether existing control measures are effective
- What actions should be taken to control a risk
- How urgently action needs to be taken.

A risk assessment should include:

(i) Identify factors that may be contributing to the risk,
(ii)Review health and safety information that is reasonably available from an
authoritative source and is relevant to the particular hazard. 40
(iii)Evaluation of how severe the harm could be. This includes looking at the types
of injuries/illnesses/harm/damage that can result from the hazard, the number of
people exposed, possible chain effects from exposure to this hazard.

(iv)Evaluation of how a hazard may cause harm. This includes examining how work
is completed, whether existing control measures are in place and whether they
control the harm, looking at infrequent/abnormal situations as well as standard
operating situations. A chain of events related to a risk may need to be considered.

(v)Determining the likelihood of harm occurring. The level of risk will increase as
the likelihood of harm and its severity increases. The likelihood of harm occurring
may be affected by how often the task is completed, in what conditions, how many
people are exposed to the hazard and for what duration.

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(vi) Identify the actions necessary to eliminate or control the risk

(vii)Identify records that it is necessary to keep to ensure that the risks are eliminated
or controlled.

Other risk factors should also be identified as they may contribute to the risk :
Including -

-The work premises and the working environment, including their layout and condition

-The capability, skill, experience and age of people ordinarily undertaking work,

-The systems of work being used

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The Risk Ranking Matrix is used to assess the likelihood and the severity or
consequences of each hazard and to give it a “risk rating”.

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 Step 3: Controlling Risks
It is not enough to just find and rate the hazards.
After finding the hazard it is important to eliminate or control the hazard before it
causes injury or illness to the personnel due to the hazard.

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 Step 4: Implement additional risk controls :
Level 1-Control Measures - Eliminate the Hazard
- The most effective control measures eliminate the hazard and associated risks.
- This can be achieved through removing the hazard or selecting alternate products or
equipment to eliminate the risk.
- If a hazard cannot be eliminated then risks can be minimized by lower control
measures.
Level 2- Control Measures
These are used to minimize the risks and involve on or a combination of the following :
(i) Substitute the hazard: substitute a substance, method or material to reduce the
risk or the hazard.
(ii) Isolate the hazard: separate the hazard from the workplace or people, Example;
a. Chemical store room, or a laboratory kept locked except to an authorized person.
b. Lock out procedures on faulty equipment.
c. Guarding for machinery. 45
(iii) Use engineering controls: modify existing machinery or plant or purchase
different machinery or plant to provide a physical solution.
Ex.- a. Trolleys, hoists or cranes. b. Guard rails.
Level 3- Control Measures
These are control options which should be considered last as they do not control the
source of the hazard but rely on human behaviour or supervision and are therefore
less effective.
They include;
-Administrative Procedures: develop work methods or procedures to reduce the
conditions of risk, for example: a. Written Safe Operating Procedures , b. Job rotation
to restrict hours worked on difficult jobs, c. Staff trained in the correct operating
procedures.
-Use Personal Protective Equipment (PPE) and training in its use:
Example : a. Handling of chemicals – gloves, safety glasses, aprons.
b. Protecting eyes from flying particles. 46
c. Protecting feet – safety boots.
References :
Brice, Andy. “A Guide to Major Chemical Disasters Worldwide.”
https://www.icis.com/Explore/Resources/News/2008/10/06/9160653/a-
Guide-to-Major-Chemical-Disasters (Accessed on 25 March 2025).

Turney R. Flixborough : Lessons which are still relevant today. Loss Prev Bull.
2014 Jun 1;237:21-6.
https://www.thechemicalengineer.com/features/flixborough-50-years-on-
lessons-for-managers-and-engineers-today/

GRADE F. Bureau of Indian Standards.

“Fire Prevention.” Health and Safety Authority,

www.hsa.ie/eng/Topics/Fire/Fire_Prevention. (Accessed on 25 March 2025).
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Joshi K, Saini K. Fire as a disaster: review of various prevention, protection
and management techniques. In Fifth World Congress on Disaster
Management: Volume IV 2023 Apr 27 (pp. 242-249). Routledge.

Gilbert E, Bakhshi S, Chang S, Terveen L. " I need to try this"? A statistical

overview of Pinterest. In Proceedings of the SIGCHI conference on human
factors in computing systems 2013 Apr 27 (pp. 2427-2436).

Kent R. Ideal Response. Maidstone, UK. IRG Limited.

https://www.idealresponse.co.uk/fire-classification-what-are-the-

different-classes-of-fire/ (Accessed on 30 March 2025).

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THANK YOU!

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