Fire Risk Assessment

1. Fire Risk Assessment
HINDUSTAN UNILEVER LIMITED
ETAH, UTTAR PRADESH
DATE OF ASSESSMENT: 08/06/2022 TO 09/06/2022

2. ACKNOWLEDGEMENT
Auditor expresses its sincere thanks to the Hindustan Unilever Plant Team for
their co-operation and unstinted help without which this assessment could not
have been possible.
The courtesy and cordiality extended to the auditor is highly appreciated.

3. I N D E X
Sr. No. Topic
1. General Information
2. Assessment Objectives
3. Assessment Scope
4. Assessment Methodology
5. Audit Team
6. List of Documents Verified
7. Fire Load Calculation
8. Observations and Recommendations
9. Attendance sheet of opening and closing meetings

4. General Information
 Plant and main product: Hindustan Unilever Limited
 No of Shifts: Multiple Shifts
 Worker Strength: 200
Assessment Objectives
 Identify opportunities to improve operational performance.
 Reduce incident rate.
 Reduce overall costs.
 Recognition to Plant Management.
 Determine the status of statutory documents and necessary compliance.
Assessment Scope
This Assessment was carried out with reference to the following standards:
NBC 2016 (Part 4)
Assessment Methodology
Following methodology adopted for successful completion of the assessment:
 Opening meeting.
 Presentation/Brief by the Plant team.
 Plant walkthrough.
 Discussions with key personnel, verification of statutory records/documents
 Close out meeting.
 Submission of the Report.
Assessment Team
Mirza Baig, Lead Auditor
Qualification: B Tech (Mechanical), PG Diploma (Industrial Safety), Lead Auditor ISO
9001, ISO 14001, ISO 45001, ISO 22001, CSP, NEBOSH, IOSH, OSHA.
Work Experience: 20 + Years (Global EHS Audit and Training)

5. List of documents Verified
Environment, Health & Safety management system documents
Sr.
No.
Document Name Availability Status
Yes No NA
1. Fire Safety management plan. Yes
2. EHS/Fire Policy. Yes
3. Organization chart Yes
4. Safety Budget Yes
5. EHS Manual Yes
6. Training records Yes
7. Fire Inspection/Internal Audit records Yes
8. Incident/near miss Reporting Records Yes
9. SOP for various activities Yes
10. Record of work permits Yes
11. Maintenance & testing record of fire protection
equipment’s
Yes
12. Accident record register. Yes
13. Safety induction records of workers and staff Yes
14. Pep talk / toolbox session records. Yes
15. Onsite emergency plan Yes
16. HIRA Yes
17. Record of Fire/Mock drills Yes
18. Approval of layouts and approvals from gov. authorities Yes
19. Records of modifications in plant Yes
20. Preventive maintenance logs and records Yes
21. Calibration and testing records Yes
22. Factory inspector register and communication record Yes
23. Factory license and License to Manufacture (Product) Yes
24. Explosive and petroleum license N/A
25. Gas Cylinders Storage License from CCE, if applicable. N/A
26. List of licensed electrician Yes
27. Approval of transformer and DG set Yes
28. Electrical maintenance record (Earth Pit, transformer oil,
lightning arrester, rubber mat etc)
Yes
29. Building stability certificate Yes
30. Fire NOC UP

7. INTRODUCTION
Fire is one of the major causes in the industrial area and there is increasing rates of fire
accidents which may kill the life of the people. The fire can cause due to three main
components such as Oxygen, Fuel and Heat is also known Fire triangle. When oxygen
supply is increased in the fire area the amount of fire burning rate increases so that heat can
be generated in huge amount. To suppress the fire one of the components must be removed.
The suitable fire extinguishers must be used to suppress the fire triangle so that fire can be
easily put off.
To suppress the fire on of the components such as oxygen, Fuel and Heat must be removed
so that burning rate of fire will be reduced. Fire alarm system is one of the essential needs
and must be installed in the building/factory where there are combustible materials present in
it. In case of fire, it is very useful to migrate and can be detected easily. Fire hydrants and fire
extinguisher must be installed where there is risk of fire. The suitable fire extinguishers must
be kept so that incase of fire it can be easily suppressed. Fire hydrants must be installed
outside to suppress the building of fire.
Classes of Fires and Fire Extinguishers
Classes of Fire Combustible
Materials
Examples Type of
Extinguisher
Class A Solid Wood, Plastic, Rubber etc Water, DCP Type
Class B Liquid Petrol, Diesel, LPG etc Foam Type
Class C Electrical Electrical Appliances CO2 Type
Class D Combustible Metals Magnesium, Potassium etc Water, DCP Type
Fire Load Calculation
Estimation of combustible material of a building can be determined by three methods they
are:
 Direct measurement of mass, with conversion based on the net heat of combustion
 Direct measurement of volume (with conversion based on a combination of density
and net heat of combustion)
 Energy release measurement by calorimetry of an item sufficiently
Fire load density is defined as the amount of heat liberated from a combustible material per
square meter in floor area. Fire load is to determine the severity and building up of fire. Fire
load is useful in determining the growth and severity of fires. The mass of the material is
calculated in kg. The calculated mass is multiplied by its calorific value in MJ/kg to get fire
load. The calculated value is then divided by area of the floor to give fire load density.
Fire load = (combustibles in kg) x calorific value in kcal-kg / Floor area in square
meters.
Calorific value of some common combustible materials
Poly Bags 17.5 Poly Propylene 42.66 Diesel 45.5
Wood 18.6 Carton box 16.9 Plastic 35
Paper (average) 16.3 Sack 16.6 Tea 4.281

8. Fire Load Calculation for PM Godown
Area: 976 SQM
Combustible
Materials
Weight in KG Calorific Value in
MJ/KG
Fire Load in MJ
Carton 92407 16.9 1561678.3
CFC 42028 1.168 49088.704
Poly 70000 17.5 1225000
Sack 16354 16.6 271476.4
Tape 1000 35 35000
Wood Pallet 4800 18.6 89280
Plastic Pallet 3000 35 105000
Fire Load Density= (1561678.3+49088.704+1225000+271476.4+35000+89280+105000)
/976 = 3231630 MJ/M3
Fire Load Calculation for Jumbo Godown
Area: 2973 SQM
Combustible
Materials
Weight in KG Calorific Value in
MJ/KG
Fire Load in MJ
Wooden Pallet 1200 18.6 22320
Plastic Pallet 15000 35 525000
Tea 600000 4.281 2568600
Fire Load Density= (22320+525000+2568600) / 2973 = 1048 MJ/M3
Fire Load Calculation for Godown 1
Area: 1394 SQM
Combustible
Materials
Weight in KG Calorific Value in
MJ/KG
Fire Load in MJ
Plastic Pallet 11250 35 393750
Tea 250000 4.281 1070250
Fire Load Density= (393750+1070250) / 1394 = 1050 MJ/M3
Fire Load Calculation for Godown 2
Area: 1394 SQM
Combustible
Materials
Weight in KG Calorific Value in
MJ/KG
Fire Load in MJ
Plastic Pallet 11250 35 393750
Tea 250000 4.281 1070250
Fire Load Density= (393750+1070250) / 1394 = 1050 MJ/M3
Fire Load Calculation for Shop Floor
Area: 1129 SQM
Combustible
Materials
Weight in KG Calorific Value in
MJ/KG
Fire Load in MJ
Carton 2850 16.9 48165
CFC 946 1.168 1104.928
Poly 9600 17.5 168000
Sack 1500 16.6 24900

9. Tape 10 35 350
Wood Pallet 384 18.6 7142
Plastic Pallet 900 35 31500
Tea 20000 4.281 85620
Ink/Makeup 16 30 480
Fire Load Density= (48165+1104.928+168000+24900+350+7142+31500+85620+480) /
1129 = 325 MJ/M3
Fire Load Calculation for Day PM
Area: 140 SQM
Combustible
Materials
Weight in KG Calorific Value in
MJ/KG
Fire Load in MJ
Carton 22648 16.9 382751
CFC 11352 1.168 13259.136
Poly 25000 17.5 437500
Sack 6280 16.6 104248
Tape 120 35 4200
Wood Pallet 4800 18.6 89280
Plastic Pallet 3000 35 105000
Fire Load Density= (382751+13259.136+437500+104248+4200+89280+105000) /140 =
8115 MJ/M3
Fire Load Calculation for Diesel Storage Room
Area: 20 SQM
Combustible
Materials
Weight in KG Calorific Value in
MJ/KG
Fire Load in MJ
Diesel 1900 45.5 86450
Fire Load Density= 86450 / 20 = 4322 MJ/M3
Conclusion
Fire load density is analyzed in the plant and the study gives following conclusion: The
maximum fire load density is found in PM Godown is 3231630 MJ/M3, Minimum is in Shop
Floor 325 MJ/M3 and the average value of fire load density in the plant is given as 463934
MJ/M3. The usage of wooden/Plastic pallets, poly bags and other carton box material can be
reduced to reduce fire load density. The Fire possibilities in the plant are solid/Liquid/Electric
fires. Since, Plant has following fire detection/suppression system in place as per the
requirement of National Building Code (NBC) 2016, part 4 and in adequate numbers;
 Dedicated firefighting/ERT team.
 Fire alarm system.
 Fire Hydrant System with hose reels and pump.
 Fire/smoke detectors.
 Portable fire extinguishers (DCP, Foam and CO2 types).
 One underground and two overhead water tanks.
 Frequent Fire drills as per statutory requirement.
 Frequent fire safety training.
 Sprinkler system.

10. Existing Capacity Additional Requirement (If any) As per
NBC 2016, Part 4
Water Tank/Pump
Under Ground – 1 Lac Litre
Overhead – 20 Thousand Litre
Not Required
(Ref. NBC 2016, Part 4 Table 23)
Fire hydrant line size- Ring, main and
branches- 4’’
No of Fire hydrant post- 13
No of Fire hose reel- 7
Not Required
(Ref. NBC 2016, Part 4 Table 23 & IS 13039)
Number of Fire Extinguisher (DCP, Foam
and CO2 Type)(5 kg, 9 kg, 20 kg)
Area No. Of FE
productionHall 20
Godown-1 9
Godown-2 8
AdminOffice FF 6
hopperSection 5
SecurityGate 4
Diesel Yard 4
Fire HydrantRoom 3
BlendArea 3
HT/LT Room 2
Scrap Yard 2
CompressorArea 2
ServerRoom 1
RestRoom 1
productionOffice 1
PCC room 1
Inkroom 1
Not Required
(Ref. NBC 2016, Part 4 Clause 5.1)
Manual Call Point- 19
Smoke Detector-196
Heat Detector- 66
Not Required
Fire Sprinklers
Jumbo Godown- 306
Godown 1- 132
Godown 2- 126
PM Store- 91
Not Required
(Ref. NBC 2016, Part 4 Clause 5.1.7)
Emergency Exit
Door Entry/Exists
Area Number
ProductionHall 4
DPMStore 2
QA Lab 2
ProductionOffice 1
Engg Store 1
AdminOffice 2
Change Room 3
Canteen 2
Dispensary 1
Not Required
(Ref. NBC 2016, Part 4 Clause 4.6)

11. Gate Room 1
PestRoom 2
TrainingRoom 1
Tea 1
PCC room 3
UPS room 2
OldToilet 1
NewToilet 2
LadiesToilet 1
Godown-1 2
Godown-2 2
PMStore 2
JumboGodown 6
Hence, there is no major requirement for fire detection/suppression in existing plant at the
moment. However, following opportunities for improvement identified during site visit.
Correction/modification will further enhance operational excellence as well as meeting
statutory requirements.
Plant falls under Moderate Hazard Industrial Building - G2 Category.

12. Opportunity for Improvements
Based on NBC 2016, Part 4
Sr.
No
Observation Recommendation Risk Matrix
1 PPE’s - SCBA (Self Contained
Breathing Apparatus) and firefighting
suits not available in the plant.
(Clause 4.1)
SCBA and firefighting suits
should be available in the
plant in adequate numbers.
2 Screening of employees/visitors
belongings/bags at security gate for
fire prone items such as lighter,
match box not evident.
(Clause 4.1)
Screening for bags should be
conducted at security gate to
ensure no fire prone items are
being brought in the plant.
3 Fire Hydrant system has one jockey
pump.
(Clause 4.1)
An additional jockey pump
may be installed to be used in
case of failure of first pump
during emergency.
4 Thermography test not conducted for
detecting electric failures/fires.
(Clause 3.4.10, Good Practices 4(9),
Part 8 section 2)
Thermography test should be
conducted by third party to
determine there is no electric
failure which may lead to
electric fires.
5 Plant has only one operational gate
for entry and exit. Emergency gate is
blocked by vehicles from outside.
(Clause 6.7.3.1)
Emergency gate should
always be free from blockage
for use in emergency
situations.
6 There is only one underground water
tank which fills two overhead tanks.
In fire emergency situation it will get
empty in 1-1.2 Hours.
(Clause 4.1 Ref. NBC Table 23)
It is recommended to have
one more underground water
tank of same capacity to
supply uninterrupted water for
at least two hours.
7 Fire safety is not included in HIRA
Chart.
(Clause 4.1)
Include it in HIRA chart and
communicate it to all
workforces through tool box
talk/induction training.
8 Emergency lighting system has
capacity of 30 minutes only.
(Clause 4.16.10)
It should be increased to 1-3
Hours.
9 PM Storage Area:
 Fire Exit sign not available
 List of trained fire fighters not
available
 Testing of hydrants and
sprinklers not done
 Access blocked partially by
materials
(Clause 4.2.7, 4.1, 5.1.1, 2.27)
 Provide exit sign board
 Display list of trained
fire fighters
 Conduct testing of
hydrants and sprinklers
quarterly
 Keep access free for
blockage all the times
10 Dust Extractor NO 3:
 Emergency ladder not  Provide additional

13. provided
 Housekeeping is in a very
poor condition
(Clause 4.11, 4.1)
ladder/stair for
emergency evacuation
 Maintain good
housekeeping to avoid
solid fires.
11 PM Plant passageway:
 Passageway obstructed by
materials.
 Fire exit signs not available
(Clause 2.27, 4.2.7)
 Passageway should be
free of obstacles at all
times
 Provide fire exit sign
board
12 Fire extinguishers kept on floor in
compressor area
(Clause 5.1.1)
All fire extinguishers should
be in hanging position, easily
assessable/visible
13 HB 07- access not clear
(Clause 5.1.1)
Clear access should be
provided.
14 Jumbo Godown:
 Fire exit sign not provided
 View of Fire extinguishers
blocked by materials
 Emergency exit gate height is
only 4 feet
(Clause 4.2.7, 5.1.1, 6.7.3.1)
 Provide fire exit sign
board
 Fire extinguishers
should be in hanging
position, easily
assessable/visible
 Either increase gate
height to 7 feet or
provide
additional/alternate
gate
15 VCB Room Area:
 Fire hydrant point missing
 Fire pipeline is 1.5 inch
(Clause 5.1.1, 5.1.1)
 Provide fire hydrant
point
 Change existing
pipeline into 4 inch
16 Transformer yard/DG Set area has
no fire extinguishers
(Clause 4.1)
Provide C type extinguisher
for transformer yard and foam
type extinguisher for DG set.
17 HB FH 11 is under emergency gate
stairs
(Clause 4.1)
Change the location.
18 Godown 2:
 HB/Extinguishers not
visible/access blocked
 Fire exit signs not provided
 No emergency exit/walkway
(Clause 4.1, 4.2.7)
 HB/Fire extinguishers
should be in hanging
position, easily
assessable/visible
 Provide fire exit sign
board
 Either provide
emergency exit gate or
create walkways all
around
19 Fire exit sign not provided in Godown Provide fire exit sign board

14. 1
(Clause 4.2.7)
20 PCC Room:
 Rescue stick and electric hand
gloves not provided
 Fire extinguishers not
provided
(Clause 4.1)
 Provide rescue stick
and electric hand
gloves
 Provide at least 2 CO2
type fire extinguishers
at each gate (Inside)
 Automatic fire
suppression system
may be provided inside
the panels for
additional safety same
as provided in diesel
storage area.
21 Shop Floor:
Contract worker, Manoj Kumar,
Contractor – Shabbir Ahmed found
painting without Induction/tool box
talk, not aware about fire procedure
and use of fire extinguishers.
(Clause 4.1)
All contract workers should go
through induction training,
daily tool box talk and fire
safety awareness training.
Opening Meeting /Closing MeetingAttendanceSheet
Sr.
No.
Name of person Name of Organization Opening
Meeting
08/06/2022
Closing
Meeting
09/06/2022
1. Mirza Baig
(Lead Auditor)
Freelancer √ √
2. Vishal Pawar
(Safety Officer)
Hindustan Uniliver
Limited
√ √
3. Hanamant Kumbhar
Manager
Hindustan Uniliver
Limited
√ √
Report Prepared and Submitted by:
Mirza Baig
--------------------------------------------- END OF REPORT----------------------------------------------