Code of practice for fire safety in iron and steel industries

IS 13694: Scope Summary & Key Points

• Scope: Fire safety in iron and steel industries, addressing fire hazards due to combustible materials (coal, fuel oil, gases, inflammable liquids, waste, etc.).
• Applies to all sizes/types of iron and steel industries.
• Emphasizes fire hazard analysis during planning and operation stages.
• Focus on safeguarding workers, equipment, and national wealth.
• Highlights need for futuristic planning to avoid haphazard growth and increased fire risk.
• Compliance with building/fire codes is necessary but may not suffice for high-value equipment protection.
• Fire safety measures should be integrated at both design and operational phases.

Related IS References (Annex A)

Important Notes

• All employees must be trained on equipment use and fire emergency response (Clause 14.5).
• Clean agent fire suppression systems are alternatives to halon systems (Amendment 2005).
• Rounding off numerical results follows IS 2:1960 rules.

flowchart LR
    A[Iron & Steel Industry Fire Safety] --> B[Planning Stage]
    A --> C[Operational Stage]
    B --> D[Fire Hazard Analysis]
    B --> E[Design Fire Protection Measures]
    C --> F[Employee Training]
    C --> G[Fire Detection & Suppression Systems]
    G --> H[Automatic Detectors (IS 2175, 2189)]
    G --> I[Portable Extinguishers (IS 2190)]

Summary: IS 13694 covers comprehensive fire safety practices tailored for iron and steel industries, integrating hazard analysis, equipment protection, employee preparedness, and adherence to related fire safety IS standards.

Key Fire Safety Considerations in Iron & Steel Industry (IS 13694)

1. Basic Design Factors (Clause 3.1):

   • Building layout, compartmentalization, and construction type.
   • Electrical installations & overhead cranes.
   • HVAC systems.
   • Peak workforce numbers.
   • Storage of fuels (oil, coal, ammonia, oxygen, sulphur).
   • Location of exits, self-closing fire doors.
   • Primary firefighting facilities for initial fire control.
   • Fixed systems: automatic fire detection, suppression, pressurized hydrants.
   • Vulnerabilities of equipment and manpower.

2. Fire Protection Systems (Clause 11.2.3):

   • Clean Agent Systems as alternatives to halon systems for fire suppression.

3. General Notes:

   • Fire safety focuses on prevention, early detection, suppression, and trained personnel.
   • Planning stage analysis of hazards and vulnerabilities is crucial.
   • Compliance with IS codes and related standards (Annex A) is mandatory.
   • Losses from fire are irreparable; hence, robust measures are essential.

Summary Table: Fire Safety Elements

Fire Safety Planning Flow (Mermaid Diagram)

flowchart TD
    A[Planning Stage] --> B[Hazard & Vulnerability Analysis]
    B --> C[Design Layout & Compartmentalization]
    C --> D[Install Fire Detection & Suppression Systems]
    D --> E[Provision of Fire Fighting Facilities]
    E --> F[Training & Emergency Preparedness]
    F --> G[Regular Maintenance & Drills]

Note: IS 13694 mainly guides major hazards and procedures; refer to related IS standards (Annex A) for detailed fire safety design, materials, and equipment specifications.

IS 13694: Fire Resistant Construction & Insulation Key Points

• Fire Resistance Rating:
  As per Clauses 4.2, 5.2, and 6.2, the fire resisting rating of construction around furnaces shall not be less than 2 hours, depending on total fire load and expected fire exposure outside the furnace.

• Fire Load Consideration:
  The rating depends on the total fire load (combustible materials) and the security against fire spread outside furnace areas.

• Employee Training (Clause 14.5):
  All steel industry employees must be trained in fire equipment use (hose reels, extinguishers) and emergency actions.

• Referenced IS Standards for Fire Protection:

  IS No.	Title
  2175:1988	Heat sensitive fire detectors
  2189:1988	Automatic fire detection & alarm system
  2190:1992	Portable fire extinguishers
  3614(Part 1):1966	Fire check doors (metal covered, rolling type)
  6382:1984	Fixed fire extinguishing system
  11360:1985	Smoke detectors

Fire Resistance Rating Summary

Conceptual Diagram: Fire Resistant Construction Zones

graph TD
    A[Furnace] --> B[Fire Resistant Wall (≥ 2 hrs)]
    B --> C[Fire Check Doors (IS 3614)]
    C --> D[Fire Detection System (IS 2175, 2189)]
    D --> E[Fire Extinguishers & Hose Reels (IS 2190)]
    E --> F[Employee Training & Emergency Plan]

Summary: Ensure furnace enclosures and adjacent structures have at least 2-hour fire resistance, use IS-approved fire doors, detectors, and extinguishers, and train all personnel in fire safety.

IS 13694: Structural & Electrical Safety Measures - Key Points

Fire Detection & Alarm Systems (Clause 10.4)

• Heat detectors (rate of rise + fixed temp.) for oil cellars, HSD storage.
• Optical detectors for cable tunnels; ionization/optical for control rooms/offices.
• Avoid beam-type detectors in steel plants due to frequent beam interruption.
• Cable tracer detectors along cable trays for temperature rise detection.
• Smoke detectors in computer rooms & false ceilings (open + false roof areas).
• Gas vapor detectors in inflammable liquid/gas storage & assembly areas.
• Manual call boxes visible, numbered, max 100m travel distance; marked with concentric circles (300 mm white, 100 mm red) for identification.
• Fire alarm system audio-visual warnings per IS 2189:1988.

Fire Extinguishing Systems (Clause 11 & 9.1)

• Follow minimum precautions in Clauses 9.2 to 9.17 to prevent fire outbreaks.
• Use portable fire extinguishers per IS 2190:1992.
• Fixed fire extinguishing systems per IS 2189:1988.

Referenced Standards (Annex A)

Summary Diagram: Fire Safety System Components

graph LR
A[Fire Hazard Areas] --> B[Heat Detectors]
A --> C[Optical/Smoke Detectors]
A --> D[Gas Vapor Detectors]
B --> E[Automatic Alarm System]
C --> E
D --> E
E --> F[Manual Call Boxes]
F --> G[Audio-Visual Warning]
G --> H[Fire Extinguishing Systems]

Note: For detailed design, installation, and spacing refer to IS 2189:1988 and IS 2190:1992.

Protection of Combustible Materials and Equipment (IS 13694 Highlights):

• Detection Systems:

  • Oil cellars, HSD storage, dust areas: Use rate-of-rise cum fixed temperature heat detectors.
  • Cable tunnels: Use optical smoke detectors and cable tracer temperature detectors (per IS 12459:1988).
  • Control rooms/offices: Use ionisation/optical detectors; place detectors in both open and false ceiling areas.
  • Gas/vapour detectors in inflammable liquid/gas storage to alarm before explosion risk.
  • Manual call boxes: Visible, numbered, max 100 m travel distance; marked with concentric circles (300 mm white, 100 mm red).

• Fire Rating & Material Protection:

  • Equipments (motors, generators) must have minimum Class A insulation.
  • Combustibles (fuel gas, oxygen pipes, lubricants) protected by circulating water, refractory or thermal insulation.
  • No cotton waste or inflammables near furnace.

• Alarm Systems:

  • Manual and automatic alarms must give audio-visual warnings at central and shop floor locations (per IS 2189:1988).

Key IS References for Fire Protection:

Summary Diagram: Fire Detection & Protection Zones

graph LR
A[Oil Cellars / HSD Storage] -->|Heat Detectors| B[Fire Alarm System]
C[Cable Tunnels] -->|Optical + Cable Tracer Detectors| B
D[Control Rooms / Offices] -->|Ionisation/Optical Detectors| B
E[Gas Storage] -->|Gas Vapour Detectors| B
F[Manual Call Boxes] -->|Manual Alarm| B
B --> G[Audio-Visual Alarm at Central & Shop Floor]

Note: Follow IS 13694 clauses 10.4, 5.6, 3.3, and 14.5 for detailed installation and operational requirements.

IS 13694 – Fire Safety for Reheating Furnace & Finishing Units

Key Specifications:

• Fire Resistance Rating: Minimum 2 hours fire-resisting enclosure (Clause 6.2).
• Clearance: Adequate clearance around furnace to ensure external surface temperature ≤ 500°C during fire (Clause 7.3).
• Instrumentation Protection: Instrument rooms and power control rooms must be insulated; cables/instruments must be shielded from direct fire exposure (Clause 6.8).
• Enclosure: Furnace and soaking pits must be fully fire-resisting, sized to process needs, minimizing fire spread (Clause 7.1).

Fire Safety Design Considerations:

Formula for Heat Transfer Limiting External Temp:

[ Q = U \times A \times \Delta T ]

• Q = Heat transfer rate (W)
• U = Overall heat transfer coefficient (W/m²·K)
• A = Surface area exposed (m²)
• ΔT = Temperature difference (K)

Design clearance and insulation to keep (T_{external} \leq 500^\circ C).

flowchart LR
    Furnace[Reheating Furnace]
    Clearance[Clearance Zone]
    ExternalTemp[External Surface Temp ≤ 500°C]
    Instrumentation[Instrumentation Rooms]
    FireResist[Fire-Resisting Enclosure ≥ 2 hrs]

    Furnace --> Clearance --> ExternalTemp
    Furnace --> FireResist
    Furnace --> Instrumentation
    Instrumentation -->|Insulated & Protected| FireResist

Summary: Design reheating furnaces with ≥2 hr fire resistance, maintain clearances to limit external temp ≤500°C, and fully insulate instrumentation to prevent fire damage per IS 13694 clauses 6.2, 6.8, 7.1 & 7.3.

Fire Resistance for Control Rooms & Service Tunnels (IS 13694)

• Fire Resistance Rating:
  Minimum 2 hours as per Clause 4.2, based on fire load and security requirements.

• Resistance Level:
  Control rooms, oil cellars, cable tunnels, and service tunnels must have fire resistance equal to the mill or furnace area (Clauses 7.5 & 8.5).

• Fire Check Doors:
  Required in oil cellars, control rooms, instrumentation racks, and service tunnels to prevent fire spread (Clause 9.5).
  These doors must comply with IS 3614 (Part 1) - 1966.

Summary Table

Key Notes:

• Fire resistance is structural and material-based, ensuring integrity and insulation.
• Doors must be fire-rated to prevent fire spread, maintaining compartmentalization.
• Design fire load and risk assessment govern exact rating but never below 2 hours.

flowchart LR
    A[Fire Load Assessment] --> B[Determine Fire Resistance Rating (≥ 2 hrs)]
    B --> C{Location}
    C -->|Control Room| D[Match Mill/Furnace Area Resistance]
    C -->|Service Tunnel| D
    D --> E[Use Fire Resistant Materials & Construction]
    D --> F[Install Fire Check Doors (IS 3614)]
    F --> G[Prevent Fire Spread]

This ensures safety and continuity of critical operations during fire events.

IS 13694: Precautions & Safety Protocols for Fire Prevention

Key Clauses & Specifications:

• Clause 9.1: Observe minimum precautions (9.2 to 9.17) to prevent fire outbreaks and equipment loss.
• Clause 14.5: All employees must be trained on fire equipment use (hose reels, extinguishers) and emergency actions.

Fire Detection & Alarm Systems (Clause 10.4):

• Heat detectors: Use rate-of-rise + fixed temperature type in oil cellars, HSD storage.
• Optical detectors: For cable tunnels; ionisation/optical for control rooms/offices.
• Gas vapour detectors: Inflammable liquid & gas storage areas to prevent explosions.
• Manual call boxes: Marked with concentric circles (300 mm white, 100 mm red), max 100 m travel distance.
• Automatic & manual systems: Audio-visual alarms per IS 2189:1988.

Fire Extinguishing System Design (Clause 3.1):

• Consider building layout, electrical installations, ventilation, worker density, fuel storage, exits, and fire fighting facilities.
• Include fixed automatic detection, suppression, and hydrant systems.
• Use fire check doors as per IS 6382:1984.

Referenced IS Standards (Annex A):

Summary Diagram: Fire Safety Protocol Flow

flowchart TD
    A[Fire Prevention Precautions] --> B[Detection Systems]
    B --> C{Detector Types}
    C --> D[Heat Detectors]
    C --> E[Optical/Ionisation Detectors]
    C --> F[Gas Vapour Detectors]
    B --> G[Manual Call Boxes]
    A --> H[Fire Extinguishing Systems]
    H --> I[Fixed Automatic Systems]
    H --> J[Portable Extinguishers]
    H --> K[Hydrant Systems]
    A --> L[Employee

IS 13694: Fire Detection and Alarm Systems – Key Points

Relevant IS Codes:

• IS 2189:1988 – Automatic and manual fire detection and alarm systems.
• IS 2175:1988 – Smoke and heat detectors.
• IS 12459:1988 – Cable tunnels protection.

Detector Selection & Spacing (Clause 10.4):

Manual Call Boxes (Clause 10.4 k, n):

• Location: Visible, easily accessible.
• Marking: White circle (300 mm dia) with inner red circle (100 mm dia).
• Spacing: Max travel distance to call box ≤ 100 m.
• Numbering: Each call box numbered and location indicated.

Alarm System Requirements:

• Both automatic and manual systems must provide audio-visual warnings at central and shop floor locations (IS 2189:1988).
• Manual call boxes integrated into the overall detection system.

Maintenance (Clause 13.1):

• Fire detection, alarm, and suppression systems must be maintained in serviceable condition at all times.

Summary Formula / Spacing Guideline:

• Maximum travel distance to manual call box:
  [ d_{max} = 100 \text{ m} ]

flowchart LR
    A[Fire Hazard Area] --> B{Select Detector Type}
    B --> C[Heat Detector (Oil Cellars

IS 13694: Key Points on Fixed Fire Extinguishing Systems

Types & Selection (Clause 11.2)

• Systems may be automatic or manual.
• Choice depends on:
  • Fire risk value
  • Local preferences
  • Occupancy & sophistication level

Fire Extinguishers (Clause 11.2.6)

• Portable extinguishers per IS 2190:1992.
• Recommended types by area:
  • Cable tunnels, oil cellars, control rooms: Foam, Foam/CO₂
  • Substations, transformers: Foam/CO₂, Powder
  • Blast furnace: Foam, Water, CO₂
  • Coke oven: Foam, Water

Detectors & Alarm Systems (Clause 10.4)

• Heat detectors for oil cellars, HSD storage.
• Optical detectors for cable tunnels.
• Ionisation/optical detectors for control rooms/offices.
• Cable tracer detectors along cable trays.
• Gas vapor detectors in flammable liquid/gas storage.
• Manual call boxes visible within 100 m travel distance, marked with concentric circles (300 mm white, 100 mm red).

Water Spray & Manual Systems (Clause 11.2.5)

• Water is primary for fire quenching but must be used carefully on hot metals to avoid explosions.
• Fire hydrants and hose reels must be installed indoors and outdoors.

Summary Table: Extinguisher Types by Area

Manual Call Box Identification

graph LR
A[Manual Call Box] --> B[White Circle (300 mm dia)]
B --> C[Red Circle (100 mm dia) inside White]
A --> D[Numbered & Location Indicated]
A --> E[Max 100 m travel distance]

This ensures quick identification and accessibility in emergencies.

For detailed design, refer to IS 2190 (portable extinguishers) and IS 2189 (fire alarm systems).

IS 13694: Fire Check Doors & Compartmentation - Key Points

Fire Check Doors (Clauses 9.5, 12.1)

• Purpose: To prevent fire spread in oil cellars, control rooms, instrumentation racks, service tunnels.
• Standard Reference: Must comply with IS 3614 (Part 1) - 1966.
• Requirements:
  • Fire resistance rating as per IS 3614.
  • Doors must withstand fire exposure for a specified duration (usually 1-2 hours).
  • Self-closing mechanisms to ensure doors are never wedged open.
  • Proper sealing to prevent smoke and flame passage.

Fire Compartmentation (Clause 13.2)

• Maintain horizontal and vertical fire compartments intact.
• Ensure walls, floors, and fire/smoke check doors are continuous and repaired promptly.
• Regular inspection of door closers and seals is essential.

Fire Extinguishers (Clause 11.2.6.1)

• Selection and installation per IS 2190:1992.
• Properly located near fire check doors and compartments.

Summary Table: Fire Check Door Specifications (from IS 3614)

flowchart LR
    A[Fire Source] -->|Heat/Flames| B[Fire Check Door]
    B -->|Blocks Fire Spread| C[Protected Compartment]
    C --> D[Safe Zone]
    B -->|Smoke Seals| E[Prevents Smoke Spread]

Note: Always consult IS 3614 for detailed construction and testing criteria of fire check doors.

Maintenance of Fire Safety Installations as per IS 13694

Key Clauses & Specifications

• Clause 13.1:
  Fire detection & alarm systems (per IS 2189:1988) and fire suppression equipment must be maintained in serviceable condition at all times.

• Clause 14.5:
  All employees must be trained on:

  • Equipment operation
  • Fire outbreak actions
  • Use of first aid hose reels & fire extinguishers

• Clause 10.4 (Detector Selection):

  Area	Detector Type	Notes
  Oil cellars, HSD storage	Rate-of-rise cum fixed temp heat
  Cable tunnels	Optical smoke + cable tracer type	High sensitivity due to positive air pressure
  Control rooms, offices	Ionisation/optical smoke detectors
  Gas storage, inflammables	Gas vapor detectors	Alarm on max vapor concentration
  General stores, labs	Detection & alarm systems	Protect costly equipment
  Manual call boxes	Located max 100 m apart, visible	Marked with concentric circles (300 mm white, 100 mm red)

• Clause 11.2.6 (Fire Extinguishers):
  Portable extinguishers per IS 2190:1992, types selected by area:

  • Cable tunnels, oil cellars: Foam, Foam/CO₂
  • Substations, transformers: Foam/CO₂, Powder
  • Blast furnace: Foam, Water, CO₂
  • Coke oven: Foam, Water

Maintenance Checklist

• Regular inspection of detectors, alarms, and extinguishers
• Functional testing per IS 2189 & IS 2190
• Training refreshers for all employees
• Clear signage for manual call points
• Documentation of maintenance & testing records

References for Detailed Specs

IS 13694 - Emergency Organization & Fire Fighting Training: Key Points

Emergency Organization Setup (Clause 14.1, 14.4, 14.5)

• Establish an emergency organization trained in:
  • First aid fire fighting
  • Use of fire detection systems (heat/smoke detectors)
  • Operation of fixed and portable fire fighting equipment
  • Actions during fire emergencies
• All employees must be familiar with:
  • Fire fighting equipment (hose reels, extinguishers)
  • Procedures during fire outbreak

Fire Extinguisher Maintenance (Clause 13.4)

• Portable fire extinguishers must be inspected and maintained as per IS 2190:1992.

Relevant IS Codes for Fire Safety Equipment (Annex A)

Summary Table: Emergency Organization Training

Diagram: Emergency Organization Flow

graph TD
    A[Emergency Organization Setup] --> B[First Aid Fire Fighting Training]
    A --> C[Detection System Usage]
    A --> D[Fixed & Portable Equipment Operation]
    A --> E[Fire Emergency Actions]
    F[All Employees] --> G[Equipment Familiarity]
    F --> H[Fire Outbreak Procedures]
    I[Fire Dept & Operators] --> J[Maintenance & Operation Training]

Note: Refer to IS 2190:1992 for detailed extinguisher types, inspection intervals, and maintenance procedures.