Fire protection and fire-fighting in silo and bin installations Risk
Contents
1. HER ii GERLING i g f HDI Gerling Risk Engineering Service Risk Engineering Guideline a AW r2 5 a rat https riskengineering services hdi gerling com thi Se Se RO oe e T a gt ec sare se Dn m A Z f 7 Py en es J OS SoA os ree eee Fire protection and fire fighting in silo and bin installations ofc 0 ag See a ww gt Sos ee E ad ay 8 ys Oh Ga per heaped NEA Se be beget 2 LARAN d w gt re Sees eels gt Ja Maa lt Risso a oda Ya 74 q N S aS Li n E A gt 1 General Insufficient preventative fire protection and ignorance of special circumstances to be observed in case of fire make fires in silos and closed bin installations the origin of major material loss and personal injury again and again Conven tional extinguishing agents and methods are hardly suit able for reliable silo fire fighting and for avoiding dust explosions The dust explosion hazard is particularly high when attempting to clear the material out of a silo loaded with hot spots or glowing nests The difficult access the building height the dust explosion hazard of the combus tible bulk material the required special fire fighting agents and the enormous amount of time needed make silo fires special cases of fire fighting Such fires can be controlled only when suitable preparation coordinated fire f2. 7 2 Experts others Emergency phone no 49 231 5333 237 available In case of Tire the Zentrum fur Brand und Explosions 24 h a day by return call www dmt de schutz Fire and explosion protection centre of DMT This office can send experts and measuring equipment to GmbH amp Co KG in Dortmund can be contacted among the site in question BASF SE Ludwigshafen 49 62 1 6043333 BASF Schwarzheide GmbH Schwarzheide 49 35752 62112 Currenta GmbH amp Co OHG Leverkusen 49 21 4 3099300 Dow Deutschland Anlagengesellschaft mbh Stade 49 41 46 912333 Henkel AG amp Co KGaA Dusseldorf 49 211 7973350 Infracor Gmbh Chemiepark Marl 49 2365 492232 InfraLeuna GmbH Leuna 49 3461 434333 InfraServ GmbH amp Co Gendorf KG Gendorf 49 8679 72222 Infraserv GmbH amp Co Hochst KG Frankfurt am Main 49 69 3056418 Merck KGaA Darmstadt 49 6151 722440 Bayer Schering Pharma AG Berlin 49 30 46814208 Wacker Chemie AG Burghausen 49 8677 832222 National Response Centre for CHEMPARK Leverkusen Dormagen Krefeld In Europe the International Chemical Environment ICE is available for information see http helid digicollection org en d Js13467e 11 2 html If the silo or bin in question holds chemical products you may also contact the Transport Unfall Informations und Hilfeleistungssystem Transportation and accident informa Risk Engineering Guideline 15 Fire protection and fire fighting in silo and bin installa
3. applies in particular An explosion protection document applying to the facility must be prepared Operating in structions must show the employees the correct and sate operation of silo and bin facilities and the proper behav iour in case of danger Rating of the fire and explosion risk must consider that organic material dust may always be combustible and or enable a dust explosion More details in specific cases can be obtained from the safety data sheets from databases for safety parameters safety literature and laboratory tests Dust may be generated even from lumpy or shredded material following abrasion inside the silo in the sur roundings and in the conveyor systems possibly causing a dangerous dust explosion When changing to storage of another material a new fire and explosion hazard analysis must be carried out The operator obligations also comprise having fire protec tion systems and electric installations including the light ning protection systems Operational Safety Decree explo sive atmospheres Technical Inspection Rules Insurer s Inspection Regulations etc inspected and maintained at regular intervals 5 Protective measures A series of tried and tested preventative and fire protec tion measures can be taken that can prevent a silo fire or minimise its consequences 5 1 Avoiding fire loads and ignition sources Throwing the product into the silo may whirl up dust especially during filling If an igniti
4. Before starting clearing out the absence of dust must be ascertained in the spaces connected with the silo and If required these must be cleaned Raising dust must abso lutely be avoided in this process While discharging the bulk material suitable measures must be taken to avoid the formation of hazardous dust air mixtures even outside the silo e g by applying a water curtain Risk Engineering Guideline Fire protection and fire fighting in silo and bin installations ines a ay Fie 3a E age E i T Picture 9 Inert gas connection to stationary evaporator Picture 10 Inert gas feeding through pre installed pipes 13 14 Risk Engineering Guideline Fire protection and fire fighting in silo and bin installations 7 Emergency addresses 7 1 Inert gas suppliers accepted for the correctness and completeness of the Suitable inert gas suppliers can be found on the homepage information as per 02 201 2 of the Industriegaseverband IGV www industriegasever In case of fire the fire brigade control stations can offer band de An extract is shown below no responsibility is assistance in procuring inert gas Hauptstelle fiir das Wilhelmstra e 98 49 2325 593 333 www atemschutzzentrum net Grubenrettungswesen D 44649 Herne Air Liquide Deutschland GmbH Hans Gunther Sohl StraBe 5 49 211 6699 0 49 211 6699 222 info airliquide de D 40235 Dusseldorf After 6 00 p m an answering www airliquide de machine is runni
5. combustion gases and feed of oxy gen into the reaction zone is possible Fires can spread through operational transport routes pipes conveyor lines thermal radiation and flying sparks Smouldering and pyrolysis gases may be generated even outside of the container which can create an explosive atmosphere Flash fire may escape through openings Opening the container and evacuating the bulk material involves a ladder ignition explosion hazard Dust explosions may occur even outside of the silo due to dust deposits The statics of the container and of the building may be affected by heating up of load bearing components and it may be overloaded by fire water and fail Swollen materials may make the container burst when in contact with water 2 2 Examples of losses 2 2 1 Fresh tankage silo A 30 t fresh tankage silo catches fire presumably due to biologically induced self ignition When no fire fighting success is achieved after actuating the existing manual CO2 fire protection system several times it is decided two hours later to call the fire brigade The fire brigade calls in a nitrogen tanker Before the tanker arrives silo discharge is started A short time later a whooshing noise is sud denly perceived from inside the silo Flames of several metres length come out of the upper silo manhole de stroying the silo and the conveyors and setting the sur rounding storage hall on fire It must be assumed that fresh air entering duri
6. in the corresponding inert gas quantity Feed rates of 0 5 to 1 0 m3 of inert gas gaseous per m3 of bulk material reduce the oxygen content to lt 2 by vol This is necessary for extinguishing the glowing fire within the bulk material and must be maintained during an ex tended period usually 48 hours Here as well an inert gas feeding period of four hours Is aimed at The precondition in each case is that the silo is relatively gas tight and or can be sealed temporarily otherwise the inert gas quantities needed may be substantially larger In addition the actual silo filling level should be checked regardless of automatic level indicators which may occa sionally be defective or imprecise 6 1 2 Storage and purchasing of inert gas Inert gas can be ordered as an emergency supply from major gas suppliers However several hours may pass until the gas delivery arrives at the silo in question This is un critical in most cases because a smouldering fire inside the silo spreads only very slowly and there often Is no other promising fire fighting method available anyway depend ing on the material stored All persons involved must be prudent and above all patient Both cylinder bundles gaseous inert gas and tank lorries liquid inert gas can be delivered One road tanker with 20 000 kg of liquid nitrogen on a semi trailer yields around 17 100 m of gaseous nitrogen A drawback of tanker deliveries is that the inert gas tan
7. parts for feeding existing fire protec tion systems and for extinguishing cleared out glowing nests The fire water supply should be at least 192 m3 h 3 200 I min for two hours duration When fixed fire protection systems are involved an independent fire water supply must be sized in accordance with the design and kept available For manual fire fighting at the silo top a dry riser which can be fed from a safe area in the ground floor should be available in the silo building for the fire brigade This riser can also be used for inertness upward gas transport This pipe must be equipped with C and or B couplers accord ing to DIN 14 302 and should have a diameter of at least DN 65 or even larger depending on the situation All pipes must be earthed for protection against electrostatic charges connection to equipotential bonding 5 7 Fire protection organisation According to the Operational Safety Decree an explosion protection document must be prepared and updated for stored materials that are susceptible to dust explosions All inspections required by the Operational Safety Decree must be carried out at regular intervals Operating instructions should be prepared for work near silos and bins entry permit cleaning schedule etc No hot work is allowed near silo facilities and inside the silo or increased safety measures must be taken with the silos being completely empty and cleaned free of dust See also the Technica
8. sion diverters In such a unit the conveying direction of the material to be transported is redirected at an acute angle so that the main excess pressure direction can be relieved through a rupture disc arranged in the direction of trans port All conveying systems must withstand the reduced explo sion excess pressure when pressure relief units are pro vided To prevent transmission of dust explosions to other silo cells or conveyor systems the individual units must be isolated from one another from an explosion protection point of view To achieve this rotary valves or explosion diverters are usually installed Special explosion protection valves and quick acting gate valves for pneumatic convey ors which close within fractions of a second are also avail able In such a configuration the conveyor systems must withstand the Tull or the reduced if pressure relief is pro vided explosion pressure In addition explosion suppres sion systems can be installed that suppress a starting ex plosion by spraying In an extinguishing agent extinguish ing powder water very quickly When used for isolation purposes these systems are referred to as extinguishing agent barriers Even conveyor systems equipped with extin guishing agent barriers or explosion suppression systems must be designed to withstand a reduced explosion excess pressure 5 4 Structural fire protection Silos and bins must be stable and sufficiently strong ac cording to
9. so that they cannot be covered up with material See also EN IEC 60079 Explosive atmospheres Conductive silo cells must be earthed or connected to equipotential bonding to counter act static electricity see VDE standards Static electricity may also occur in filling and conveying operations and when pouring substances into another container Such processes require equipotential bonding measures as well especially including the vehicles connected with opera tional facilities such as lorries and railway wagons See also NFPA 77 and Cenelec CLC TR 50404 High silo buildings should be equipped with a lightning protection system according to DGUV Information 209 045 former BGI 739 2 This system must be completed in accordance with DIN EN 62305 VDE 0185 305 5 2 Permanent inertness In case of bulk material with a heavy self ignition tendency such as some hard coal grades or coal dust operation of the silo and bin facilities in a permanent inert gas atmos phere is recommended A constant feed of inert gas usually nitrogen keeps the silo atmosphere permanently below a critical oxygen concentration which is between 2 and 12 by vol depending on the bulk material This avoids a Tire from the start but inert gas escaping during silo filling and draining processes must be permanently replaced This may cause considerable costs 5 3 Design measures for explosion protection This comprises all measures involving well aimed discharge
10. the general technical rules Dimensioning must take explosion protection measures into account arrange ment size static resoonse pressure and load relief capabil ity of pressure relief units and container strength for re duced explosion pressure Risk Engineering Guideline 7 Fire protection and fire fighting in silo and bin installations a tng i 7 A F f biaa A A Dan s wp i MFS Picture 2 Prepared sealing for clearing out of silo Silo and bin facilities should be built from non combustible building materials in order to avoid additional fire loads Solid silo facilities made of brickwork or reinforced con crete offer the benefit that they resist a fire well and offer good stability Silos made of metal plastic GRP or textile materials however will quickly lose their stability in case of fire and may collapse The statics may quickly fail in particular when filling fire water into such silos Moreover the electric conductivity should be ensured for silos made of plastics protection against sparks due to electrostatic charges Silo and bin facilities should be separated with a fire rating inside buildings and with respect to other buildings and plant components When setting up silos and bins out doors a minimum distance from buildings and plants of 5 m and of 10 m in case of combustible silos should be re spected especially if the silo body is not solid and there is a high danger of co
11. Engineering Insurance and Marine The focus of activities is on the identi fication and assessment of risks and the development of appropriate individual concepts for protection HDI Gerling Sicherheitstechnik is part of the global Risk Engineering Network of the Talanx Group and a wholly owned subsidiary of HDI Gerling Industrie Versicherung HDI Gerling Sicherheitstechnik GmbH Layout RELAY CORPORATE HDI Platz 1 D 30659 Hannover PUBLISHING GmbH Phone 49 511 645 4126 Printers Fax 49 511 645 4542 Linden Druck Verlagsgesellschaft mbH Internet www hdi gerling de Pictures HDI Gerling Sicherheitstechnik GmbH Imprint panthermedia net_by Phillip Minnis Robert In charge of the content Zehetmayer Z Jan Huiping Zhu happystock Michael Otte xxlphoto jirkaejc HDI Gerling Sicherheitstechnik GmbH Firma GTE Firma Westfalen AG M nster Firma Rembe Firma Zeppelin Systems Although we made every effort possible to ensure the accuracy of the information provided no liability can be assumed for the currentness correctness and completeness of the information We neither intend nor assume any obligation to update or revise these statements in light of developments which differ from those anticipated
12. O2 gas An evaporator is required Max internal silo excess pressure See manufacturer s specifications Depending on design to be measured near the inert gas feed point Measuring of fire intensity glowing fire Measure the carbon monoxide CO concentration at the silo top Decreases from gt gt 1 000 ppm to lt 100 ppm possibly to 0 in case of successful inertness Table 2 Practical guideline values for silo inertness 11 12 Risk Engineering Guideline Fire protection and fire fighting in silo and bin installations the second step inert gas is therefore also fed in at the silo bottom at the same time e g using a prepared connec tion C coupler according to DIN 14302 a lance or an outside ring line with openings protruding into the silo The oxygen concentration must be permanently measured in the silo top and bottom area Gas feeding at the bottom must be slow and at low pres sure so that the gas penetrates the bulk material evenly and no major channels form inside the bulk material The oxygen displaced from the bulk material ends up in the previously inert top space Depending on the oxygen con centration in the silo top gas feeding from the top can be reduced slowly and finally shut down altogether However should the oxygen concentration in the top space rise above e g 8 by vol again in case of organic material inert gas must again be fed in from the top Prior to filling t
13. em trouble false alarms or failure to respond general failure Universal monitoring systems that can be used for silos without restrictions are not available so far 5 5 2 Fixed fire protection systems 5 5 2 1 Inertness in case of fire The most favourable option for fire fighting and safe clear ing out in case of fire is inertness of the silo or bin In this process an inert gas nitrogen in most cases is fed into the silo or the bin so that the air and consequently oxygen is displaced from the silo and the oxygen content drops below 4 6 by vol At this oxygen concentration fire spread in the usually stored materials is no longer possible Dust explosions of organic materials food and fodder wood coal and plastics are no longer possible as early as below 8 by vol oxygen limit concentration The oxy gen limit concentrations depend on the material and are between 3 by vol magnesium and 14 by vol hard coal see table 1 In case of fire you should subtract at least 1 by vol from the values in the table as a safety margin Nitrogen as an inert gas offers the advantage that It is a little more lightweight than air and non toxic but it dis places oxygen It is true that carbon dioxide has slightly Picture 3 Examples of explosion proof smoke detectors better fire fighting properties but is toxic in higher con centrations and above all is heavier than air thus accumu lating in lower level rooms Th
14. extinguished or the conveyor system is shut down immedi ately Spark extinguishing systems have proved their worth for extinguishing substances in conveyors The decisive aspect here is that the bulk density within the conveyor system is not too high covering up glowing nests and sparks and that the stored material is not too sensitive to water Soiling of spark sensors can be removed e g by compressed air cleaning of the optical units These reasons among others necessitate that design and installation are by a VdS approved spark extinguishing systems company in accordance with VdS guideline 2106 5 1 2 Ignition sources on and in the silo When an explosive atmosphere is specified inside the silo so called explosion zones see Operations Guideline 1999 92 EC electric and non electric devices and systems in Europe must meet the requirements of ATEX Product Guideline 94 9 EC explosion protected equipment Risk Engineering Guideline Fire protection and fire fighting in silo and bin installations Similar laws and regulations govern the purchasing re quirements outside of Europe These must be regularly checked by a capable person according to the Operational Safety Decree every three years at the latest Electric installations e g lights should not be installed inside the silo if possible All electric equipment including lighting fixtures in explosive atmospheres must be suitable for use in explosive atmospheres and arranged
15. he filling lines with the inert gas these lines must be vented and or flushed with the inert gas so that no additional oxygen is blown into the silo The process of creating inertness must be monitored by measurements The parameters below must be measured on the silo top m oxygen concentration carbon monoxide concentration temperature inside the silo if required carbon dioxide concentration if required The pressure inside the silo must be monitored at the silo bottom near the inert gas feeding point If the necessary connections and openings are not pro vided on the silo these must be made available temporar ily if necessary by drilling holes into the silo only in the bulk material area and while using water for drill cooling In this process explosion protection must be observed Igniting sparks and hot surfaces must absolutely be avoid ed The filling and extinguishing process may take from several hours to some days The CO concentration is used to determine if the fire has been extinguished A perma nent CO concentration of lt 30 ppm after finishing the inertness process no more inert gas feeding indicates successful fire fighting 6 2 Use of water foam Fire water with wetting agent medium and high expan sion foam or extinguishing gel can be applied for cooling and or covering up the bulk material under inert gas pro tection The use of fire water and foam inside the silo is usually impossible if the substa
16. ighting and patience are provided he WANN Silo fires are special fires and require special measures from operating companies fire brigades and specialist consultants Proper planning and the right measures in case of e S 2 Risk situation and examples of losses 2 1 Risk situation Silos closed bins and similar large scale containers serve for storing loose bulk material The container sizes are quite different and may reach up to several thousand cubic metres Silos can be made of steel concrete plastics GRP wood or textile materials Loose bulk material can be avail able in the following conditions as dust e g fibre dust plastic powder as grains e g cereals plastic pellets as lumps e g coal potatoes as mush e g mud as machined pieces e g wooden chips as shredded pieces e g plastic waste Ignition sources frequently include self ignitions or intro duced sparks and glowing nests Organic bulk materials e g food and fodder may tend to self ignition when stored too long or in conditions that are too moist or too hot Basically solid bulk material may ignite itself when the storage temperature is sufficient for igniting the existing bulk volume or vice versa e when the bulk volume is large enough for being ignited at the pre vailing storage temperature the storage duration at the prevailing temperature is longer than the induction time the discharge of
17. is may become dangerous for fire fighters in an inert silo if the inert gas feed point is below ground level or carbon dioxide escapes from other silo leaks and accumulates beneath the silo In addition it may react to produce explosive carbon monoxide at very high temperatures To achieve well designed and rapid inertness of a silo or bin involves fitting permanently installed gas pipes to the silo top and closing gas feed and measuring sensor con nections gas pressure approx 15 cm A C pipe con nection DIN 14302 as a nozzle or annular channel is use ful for gas feeding and the pipe should be installed so that it cannot be clogged by the bulk material The inert gas connections should be provided at the top and the bot tom Suitable sealing fixtures shall be provided for the silo top and bottom area At least three closing 1 2 openings should be provided for measuring sensors these should be located at the silo bottom between the discharge and the inert gas feed at half the silo elevation and at the silo top In addition a ventilation opening should be provided at the silo top in order to discharge displaced air Picture 4 Smoke detector in a practical application 5 5 2 2 Spray water systems The installation of stationary spray water systems inside silos and bins is recommended for bulk materials that can well be extinguished with water e g wood chips and dust as well as paper chips and dust Design and installatio
18. k in gaseous condition only during the first roughly three hours and the residual pressure must not drop below 0 5 bar After that evapo ration from the liquid to the gas phase is needed which can be realized only with a separate and suitably dimen can be withdrawn from the N g Incomplete fire fighting and early clearing out Guideline values for silo inertness overview Oxygen concentration against dust explosion Limit oxygen concentration T ofa silo often results in dust explosions with fatal consequences lt 8 0 by vol for organic material on average Risk Engineering Guideline Fire protection and fire fighting in silo and bin installations sioned evaporator unit Nitrogen cylinder bundles how ever can be used continuously until completely empty this does not apply to CO2 cylinders In an optimum configuration inert gas can also be stored in the operations e g in cylinder bundles or liquefied gas tanks with evaporators In this way the process of achiev ing inertness in a silo or a bin can be started early in case of fire and continued by gas delivered later The gas quan tity to be stocked depends on the silo size It should be sufficient for creating inertness for four hours In the exam ple above and when supposing an unfavourable filling degree of only 10 of the silo volume there would be 1 800 m3 of empty top volume so that 1 800 m3 x 1 5 m3 of nitrogen m3 2 700 m of nitrogen would be req
19. l Safety Information on the subject matter of Hot work Smoking is not allowed This ban must be clearly communicated by means of signs A sufficient number of employees must be instructed in how to act In case of a silo fire and in the handling of the safety equipment in the silo and bin facilities Practical fire extinguisher training using a training unit is also strongly recommended An alarm plan should indicate who must be informed in case of fire e g company management fire brigade inert gas supplier technical advisor employer s liability associa tion trade supervision fire insurer fire protection dept The inert gas suppliers must be contacted in order to find out which suitable gases and quantities as well as necessa ry equipment evaporator can be supplied within which time The practical fire fighting measures must be discussed in advance with the fire brigade in charge and regular exer cises must be performed Fire brigade plans providing the necessary information and design documents of the silo and bin facilities as well as the present Technical Safety Information should be handy on site for the fire brigade and for technical advisors experts 5 8 Maintenance Regular maintenance of filters moving parts including bearings and hinges and the existing safety equipment of the silo and bin facilities according to the manufacturer s specifications is urgently required 6 Measures in case of fire After notif
20. llapse When setting up silos and bins inside buildings the walls and ceilings of the building should be fire resistant F90 according to DIN 4102 As for the rest the minimum requirements of DGUV Information 209 045 must be met Essential inertness of the silo in case of fire necessitates that all openings can be made as gas tight as possible even temporarily so that the inert gas cannot escape quickly As far as the subsequent clearing out of the silo is con cerned access hatches at different silo body elevations inside diameter 0 60 m min and additional emergency clearing openings at the silo base have proved their worth from there the stored material can be transported to a safe area and extinguished if necessary Special requirements on the condition of silos and bins and their surroundings may apply to the storage of special bulk materials due to provisions imposed by authorities or em ployer s liability associations See also chapter 8 5 5 Fixed fire protection These measures are to serve for detecting and or fighting a fire 5 5 1 Silo monitoring In addition to the usual technical monitoring equipment such as level indicators and overfilling protections silos and bins should also be monitored for internal fire The simplest measure frequently involves permanently installed temperature sensors or measuring lances provided at dif ferent elevations of the bulk material However their dis advantage is that they reac
21. n must comply with VdS guideline 2109 Spray water sys tems and as far as wood Is concerned DGUV Information 209 045 The water applied should be at least 7 5 mm min I m2 x min Activation may be either manual or automatic e g by an activation pipework frequently seen in bins or by automatic fire alarms The fire protection systems of smaller silos may also be installed as dry semi fixed sys Example Silo dimensions height 40 m diameter 8 m Risk Engineering Guideline Fire protection and fire fighting in silo and bin installations tems supplied by fire water from hose reels or by the fire brigade in case of fire Filter systems using textile components in suction systems should also be fitted with manual automatic or semi Stationary spray water systems Electric fire water booster pumps must be relied upon in the event of a fire and should therefore be connected to an emergency power supply 5 5 2 3 Gas protection systems Gas protection systems are suitable for silos and bins only with reservations The working principle relies on inertness _ Limit oxygen concentra tion with nitrogen Substance inertness in by vol Silo cross section area 4mx4mx 3 14 50 m Ba Aluminium 5 Total silo volume 50 m x 40 m 2 000 m organic material sa Brown coal 12 Filling level 24 m 60 i e 800 m of empty top space 1 200 m3 of bulk material Cellulose 9 Inert gas quantity in t
22. nces in question are swollen or if the bulk material will not impregnate well with water forms lumps or the silo is made of metal plastics or textile materials and will not tolerate increased weight due to water danger of collapse The use of fire water without additives full jet spray jet inside the silo should be avoid ed When using water near the silo ensure that no dust is whirled up use a spray jet and that the water will not flow into silo cells Silo cooling from the outside using water is usually possi ble and makes sense 6 3 Clearing out of silo Clearing out of the silo may be started only after the fire is completely extinguished The CO concentration is used to determine if the fire has been extinguished A permanent CO concentration of lt 30 ppm after finishing the inertness process no more inert gas feeding indicates successful fire fighting If the fire cannot be extinguished the silo must be cleared out under an inert atmosphere both inside the silo and in the associated conveying systems The decision about when to start clearing out must be made by an expert in cooperation with the Tire brigade Failure to observe this procedure involves the danger of another fire or a dust explosion while clearing out the silo A glowing fire may have created so called bridges inside the silo which may collapse while clearing out the silo and whirl up dust A dust explosion may follow if there is no more inert atmosphere
23. ng providing an emergency number Linde AG Seitnerstr 70 49 1803 85000 0 info de linde gas com Gases Division Germany D 82049 Pullach Emergency call no outside of www linde gas de business hours 49 89 7446 2333 AIR PRODUCTS Rensingstr 15 49 234 6105 60 49 234 6105 6371 www airproducts de GmbH 44807 Bochum Riemke Emergency call no outside of business hours 49 69 50985368 KRAISS amp FRIZ BahnhofstraBe 64 49 7151 709966 0 49 7151 709966 22 info kraissundfriz de Autogenwerk D 73630 Remshalden Only in Baden Wirttemberg www kraissundfriz de Postcode 7 PRAXAIR Kennedyhaus 49 211 2600 0 49 211 2600 123 contact Jjermany praxair com Hans Bockler Str 1 Www praxair com Emergency call no outside of D 40476 D sseldorf business hours 49 180 201 0000 WESTFALEN AG Industrieweg 43 49 251 695 0 49 251 695 194 info westfalen ag de D 48155 M nster Emergency call no outside of www westfalen ag de business hours 49 5459 80625 Equipment 49 251 695 228 BASI SCH BERL Im Steinger st 57 49 7222 505 0 49 7222 505 298 info basigas de GmbH amp Co KG D 76437 Rastatt www basigas de MESSER GROUP Messer Platz 1 49 6196 7760 0 49 6196 7760 442 info messergroup com GmbH D 65812 Bad Soden Wwww messergroup com RIEBNER GASE Rudolf Diesel Str 5 49 9571 765 0 49 9571 765 67 gase riessner de GmbH amp Co KG D 96215 Lichtenfels Emergency call no www riessner de 49 173 8877930
24. ng the discharge process product level dropping has started the flash fire The fire can be extinguished only one hour later after calling in more fire fighters The loss suffered is more than one million Risk Engineering Guideline 3 Fire protection and fire fighting in silo and bin installations 2 2 2 Coal silo Slight smoke development is perceived on a 3 000 t rein forced concrete hard coal silo on the site of a power station The temperature and carbon monoxide sensors provided inside the silo respond by signalling a smoulder ing fire The fixed foam type fire protection system on the silo head is activated and also the fire brigade is called in and smoke is reduced Assuming that the fire has been extinguished discharging the silo starts some hours later under supervision of the fire brigade In the morning of the second day a powerful explosion suddenly occurs while discharging the silo very likely intensified by ingress of fresh air making the 250 t concrete silo roof collapse and destroying the conveyors on the silo head The silo was not equipped with an explosion pressure relief arrangement Provision of this safety feature although obvious is often missing from coal silos The fire brigade now orders the silo to be opened with a wrecking ball This work takes another six days The silo suffers total loss and the sur rounding plants are damaged The power station had to be shut down temporarily The loss suffered was just
25. of excess pressure which avoid damage to the silo body and the pneumatic conveyors in case of a dust explosion Dust explosions can create an excess pressure level of up to 8 bars Pressure relief must be to the outside and with out any hazards If this is not possible technical measures must be taken that enable safe control of the excess pres sure e g quenching unit The examples listed below describe some possible measures that must be defined in a protection concept and matched to one another The most frequently applied measure is to provide explo sion pressure relief areas on the silo head e g by install ing rupture discs rupture flaps or breaking films which relieve the pressure either to the top or laterally The silo containers must be designed to withstand the reduced explosion pressure resulting from the pressure relief The size of the necessary pressure relief areas is calculated among others as a function of the dust explosion hazard of the substance KSt value and of container shape and size Precise calculations can be found in VDI guideline 3673 or in DIN EN 14491 Mechanically closed conveyors such as elevators can also be protected by pressure relief units such as rupture discs and pressure relief flaps In that case the conveyors must be designed to withstand the reduced explosion pressure a i sw ai Picture 1 Examples of rupture discs Pneumatic conveyors may be protected by so called explo
26. on source is present a dust explosion may result Additional fire loads from dust deposits near the silo must be kept to a minimum by regular cleaning Ignition sources inside the silo and around the silo must absolutely be avoided Risk Engineering Guideline Fire protection and fire fighting in silo and bin installations 5 1 1 Avoiding introduction A cell occupation and control schedule can avoid mixtures and critical conditions can be identified and traced This can reduce the risk of self ignition inside the silo e g due to introduction of moisture The moisture content of stored materials tending to self ignition in connection with moisture should be examined before storing Silo ventila tion can serve for keeping the moisture content of the stored material low The formation of hot of burning material glowing nests and sparks and or spark generating parts must be avoided efficiently as early as in the conveyor systems to the silo Safety monitoring of conveyors off track monitors slip control soeed measurement and temperature control as well as metal separators serve this purpose Transportation of hot or burning substances e g glowing nests by conveyors to the silo must be effectively prevent ed To this end infrared sensors hot spot sensors or spark detectors can be employed However these make sense only if after detecting a hot or burning substance this substance Is either reliably discharged automatically or
27. op space 800 m x 1 5 m3 of nitrogen m 1 200 m of nitrogen Wood 10 Inert gas quantity of bulk material 1 200 m x 0 5 1 0 m of nitrogen m 600 1 200 m3 of Magnesium nitrogen pre alloy 3 Feed rate in top space 1 200 m3 4 hours 300 m3 h Maize starch 9 Feed rate in bulk material 600 1 200 m3 4 hours 150 300 m3 h i Polyacrylnitrile 10 Plus more inert gas for maintaining the concentration leaks depending on the silo in question Polyethylene PE 10 Carbon black 12 Hard coal 14 at ALY Picture 5 Inert gas delivery by tank lorry with a mobile evaporator Table 1 Limit oxygen concentrations of various dusts from VDI 2263 2 9 10 Risk Engineering Guideline Fire protection and fire fighting in silo and bin installations However the technical effort required is quite considerable because the entire extinguishing gas quantity needed must be stored As compared with conventional gas protection systems the flooding periods are much longer roughly one to two hours The goal of keeping the extinguishing and or inert gas inside the silo during many hours or days cannot be achieved by using gas protection systems alone A continuous inert gas feed during an extended period of time is required because silos are usually not 100 gas tight and the extinguishing and or inert gas will slowly escape 5 6 Fire water supply Sufficient water supply is necessary for initial measures for cooling building
28. rotection can basically be all non combustible and non oxidizing gases not reacting with the substance and or the dust e g nitrogen carbon dioxide and argon Inertness To create inertness means filling a volume with an inert gas in the sense of fire and explosion protection in order to displace oxygen so that combustion explosion inside this volume is no longer possible Spray water system Spray water systems serve for feeding fire water to the fire in a very well designed way This can be achieved by a dry pipe fire protection system with signalling to the fire bri gade or by pipes that are permanently connected to the water supply and activated either automatically or manu ally in case of fire Safety parameters Safety parameters is a collective term for substance proper ties of combustible dust according to VDI 2263 sheet 1 4 Operator obligations The obligations of operators of silo and similar facilities include among others analysis and documentation of pos sible fire and explosion hazards and taking the necessary safety measures This is done using a risk analysis that the operator must carry out prior to putting the facility into operation for the first time The essential element is to consider all operating conditions starting with construc tion putting into operation operation maintenance and cleaning up to dismounting and disposal As far as explo sion hazards are concerned the Operational Safety Decree
29. s 10 2011 Pressure relief of dust explosions 11 2002 sheet 1 Dust fires and dust explosions 05 1992 Dust fires and dust explosions inertness 05 1992 Annex 9 Outline in principle of silo fire fighting overview Mig Cylinder rack P gt gt gt T0 T 4 4 te or oh a ie L006 6 6 gt gt gt gt KARL gt gt D gt gt 4 4 4 4 AFF 1 Initial inerting from above 4 RE Eoo l Foam injection only if there is an open fire Cooling XN Ra amp a Ri A R a Pu ae o 6 e a Ps Se Smouldering fire Riser line ys Measure O2 CO CO2 Temp 2 Inerting from below My 16 Risk Engineering Guideline 2 14 I1 14 500 N 403 HGST SIFI156GB Fire Protection and Fire fighting in Silo and Bunker Plants About HDI Gerling Sicherheitstechnik HDI Gerling Sicherheitstechnik supports mid size companies industrial companies and groups in preventing loss and damage and in setting up a company risk management system HDI Gerling Sicherheitstechnik also offers customers access to more than one hundred engineers and technical specialists from a wide range of different disciplines The goal is to support companies in managing risks and working out an individual risk based concept for insurance cover HDI Gerling Sicherheitstechnik operates across the world in the technical safety lines of Fire Motor
30. t avoiding accidents and health hazards In addition the operating instructions serve as a basis for training A distinction is made between operating instructions de scribing how to handle hazardous substances and operat ing instructions describing how to operate machinery and plants Only hazardous and or safety relevant work pro cesses are dealt with To this end the operating instruc tions contain the necessary information provided in the user manual for technical products or the safety data sheets for hazardous substances issued by the producer importer or supplier Explosion pressure relief Pressure relief devices serve for discharging the excess pressure in a well designed way in the event of an explo sion in order not to endanger the stability of a silo or a bin The required pressure relief surfaces and container stability values can be calculated from the specifications in VDI 3673 or DIN EN 14491 In an explosion and when the pressure relief system responds persons must not be en dangered by ejected or falling parts and by possible effects of pressure and flames Inert gas Low reactivity gases participating in few chemical reac tions only are referred to as inert gases However it de pends on the specific case whether a given gas is referred to as inert gas for a given application Examples of inert gases are nitrogen and all noble gases i e argon and helium Inert gases in the sense of fire and explosion p
31. t quite slowly or do not detect the fire at all and that experience tells us that before they respond smoke can already be seen escaping from the silo Smoke detectors detecting typical smouldering gases e g carbon monoxide CO and methane CH4 very early are better suited for this purpose Depending on the material stored a high carbon monoxide concentration is frequent ly found inside a silo holding e g coal or wood pellets plus air humidity and fine dust so that smoke detectors detecting CO exclusively can be used only with restrictions Oxygen sensors may also serve for fire monitoring Conventional smoke sensors are less suited inside the silo as they soil quickly They can be installed in spaces above the silo tops if required and possibly as smoke intake sys tems as far as the amount of dust produced is low Special filters and dust separators for smoke intake systems have been developed for use especially inside silos so that now smoke monitoring is possible depending on the material stored In open bin facilities stationary thermal image cameras are often suitable for early fire detection At any rate the automatic monitoring concepts must be adapted specifically to the local conditions Engineering design by a specialist is required because incorrect selec tion of equipment and wrong locations of fire alarms may Risk Engineering Guideline Fire protection and fire fighting in silo and bin installations result in syst
32. tions 7 3 Contribution The Zentrum tur Brand und Explosionsschutz Fire and explosion protection centre of DMT GmbH amp Co KG in tion and help system TUIS 8 Further reading VdS 2154 VdS 2106 VdS 2109 EN 14491 EN IEC 60079 NFPA 68 NFPA 77 NFPA 654 DGUV Information 209 45 suvaPro SP 2006 47 Silo fires VDE 0185 305 DIN EN 62305 DIN VDE 0185 305 VDI 3673 1 VDI 2263 VDI 2263 2 Dortmund has actively contributed to the content and layout of the present Safety Information Inertness of silos in case of fire 01 2008 www vds de Spark extinguishing systems 05 2003 Spray water extinguishing systems 06 2002 2109 S1 08 2005 Protection systems for pressure relief in dust explosions 10 2012 Explosive atmospheres 04 2013 Standard of explosion protection by deflagration venting 2013 Recommended Practice on Static Electricity 2014 Standard for the prevention of fire and dust explosions from the manufacturing processing and handling of combustible particulate solids 2013 Exhaust systems and silos for wood dust and chips fire and explosion protection 12 2010 former BGI 739 2 Check list for wood chips silos 11 2008 order no 67007 d Switzerland www suva ch Extinguishing Silo Fires 2006 SP Technical Research Institute of Sweden report no 2006 47 www sp se Training documents of Frankfurt a M fire service 01 2008 download from www feuerwehr frankfurt de Lightning protection system
33. uired equalling around 3 160 kg 6 1 3 Task of inert gas and fire extinguishing As a basic rule the top space should be made inert first This serves as a protection against possible dust explosions in the empty top volume which has priority for the time being However feeding in inert gas from the top alone opposed to the thermal lift usually cannot penetrate the bulk material in the silo and therefore not completely extinguish the glowing fire which in turn is a precondition for clearing out the silo without hazards In Remarks Applies to clearing out of the silo in this process measure the oxygen at the silo bottom and top Oxygen concentration 02 against fire spread 4 6 by vol O2 max Measure the oxygen at the silo top Maintain this concentration for at least 48 h Oxygen concentration 02 for extinguishing lt 2 by vol 02 Measure the oxygen at the silo top Maintain this concentration for at least 48 h Inert gas feed quantity in top space for oxygen concentration lt 8 by vol Inert gas feed quantity in bulk material for oxygen concentration lt 2 by vol 1 0 1 5 m3 per m of empty silo volume 0 5 1 0 m per m of bulk material volume N2 1 5 m3 m3 of empty volume CO2 1 0 m3 m of empty volume Regardless of inert gas Tank lorry load liquefied nitrogen liquefied carbon dioxide approx 20 000 kg liquefied approx 17 100 m N2 gas approx 10 820 m C
34. under 10 million 2 2 3 Wood chips silo Smoke Is seen escape through the top hatch of a wood chips silo The fire brigade opens the top hatch from its turntable ladder and detects heavy smoke generation but no flames Now the silo bottom hatch is opened in order to discharge the silo content and extinguish any possible fire pockets The fire brigade discharges the wood chips out of the silo using shovels with the chips getting darker and soon totally black Suddenly a flash fire comes out of the bottom hatch and injures a fire fighter Presumably dust whirled up combined with the high temperatures and ingress of oxygen upon opening caused this sudden com bustion The fire brigade Is on the site for more than twelve hours in total before the silo Is finally discharged and completely extinguished Risk Engineering Guideline Fire protection and fire fighting in silo and bin installations 2 2 4 Cereals silo An explosion occurs while fighting a fire on a cereals silo making the concrete roof of the eleven storey silo collapse and killing two fire fighters Another six fire fighters are seriously injured The operator is sentenced to several years of prison for lack of preventative fire protection 3 Terms Operating instructions The operating instructions in the sense of Safety Informa tion are instructions issued by the employer to the em ployees They define the behaviour on the site regarding workplace and work and aim a
35. ying the offices in charge fire brigade technical advisor in case of fire all conveyors should be shut down and to prepare inertness closing all silo openings as gas tightly as possible should be started if necessary using wet bags panels adhesive tape or similar things This avoids further oxygen ingress In this process it must be ensured that no persons are endangered by smoke and If required respiratory equipment must be worn fire brigade In addi tion further adjoining silos not affected by the fire should be emptied if possible in order to avoid fire spread 6 1 Inertness The inert gas quantity required must be calculated and made available The process to achieve inertness should only be started when enough inert gas is available and further supply is ensured Moreover continuous gas measurements are required among others m oxygen in order to prove sufficient inertness m CO determination of fire intensity and fire fighting SUCCESS m the measured values course must be assessed on site by an expert 6 1 1 Required inert gas quantities As practical experience has shown achieving an inert emp ty silo top space requires 1 m3 of carbon monoxide gase ous or 1 5 m3 of nitrogen gaseous per m of empty top space This reduces the oxygen concentration to less than 8 0 by vol so that there is no more dust explosion haz ard for organic substances in the top space A four hour period is aimed at for feeding
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