Code of practice for fire safety in iron and steel industries
1993 Edition

The recommended fire suppression equipment for iron and steel plants includes:

• Water-based sprays and hydrants as the primary extinguishing agents, particularly effective in areas such as fuel oil storage, oil cellars, outdoor transformers, sintering plants, sponge iron, and coal storage. Sprinkler systems are efficient in controlling early-stage fires in these locations.
• Sprinkler systems are unsuitable for cable tunnels, blast furnaces, steel melting shops, hot rolling mills, coke ovens, and oxygen or acetylene plants due to the risk of explosions when water contacts hot metal surfaces.
• Detection systems include heat detectors for oil cellars, HSD storage, and dust-prone zones; optical detectors for cable tunnels and control rooms; gas vapor detectors in flammable liquid and gas storage areas; and strategically placed manual call boxes with clear marking and a maximum travel distance of 100 meters.
• Open main shops with static equipment generally do not require automatic detection, whereas general stores and laboratories should have detection and alarm systems.

This tailored approach ensures optimal fire risk mitigation across diverse plant sections.

To reduce fire risks when storing inflammable liquids and lubricants as per the standard:

• Store small quantities within specially insulated enclosures or maintain them under an insulated atmosphere to prevent accidental ignition.
• Combustible materials such as fuel gases, oxygen pipelines, lubricants, and flammable liquids should be safeguarded using circulating water cooling, refractory materials, or thermal insulation.
• It is prohibited to keep cotton waste, inflammable liquids, or lubricants near furnace areas to avoid fire hazards.

These measures collectively ensure containment of heat and avoidance of ignition sources, thereby minimizing fire outbreak potential.

In accordance with the standard's fire resistance criteria:

• Furnaces must have a fire-resisting construction rating of at least two hours, depending on the total fire load and anticipated fire exposure.
• Control rooms require a minimum fire resistance rating of one hour, considering the fire load and security needs.

These ratings are critical to ensure sufficient protection against fire propagation and safeguard vital operational zones.

To avert fire hazards during welding and flame cutting operations, the following protocols should be followed:

• Operations must be conducted under strict supervision with a formal fire safety plan detailing precautions and assigned responsibilities.
• Only trained personnel equipped with adequate firefighting tools should monitor the activities.
• Welding is prohibited in no-smoking zones unless comprehensive safety measures are adhered to.
• Continuous fire watch is mandatory during and after the operation to detect smouldering fires, including inspection of adjacent floors and areas.
• Additional fire watch personnel should be deployed if multiple floors are susceptible.

Consistent vigilance and preparedness are essential to prevent fires in such high-risk activities.

The standard prescribes organizing dedicated emergency firefighting teams with the following attributes:

• Teams must be trained in first aid firefighting techniques, including the use of fire detection devices, fixed and portable firefighting equipment, and emergency response actions.
• All plant personnel should be trained in the operation of firefighting apparatus such as hose reels and portable extinguishers.
• The firefighting department and plant operators must receive instruction on the maintenance and operation of fire safety equipment.
• Portable fire extinguishers should be regularly inspected and maintained in compliance with relevant IS specifications.

This structured training ensures effective response capabilities and minimizes fire-related risks within the facility.