1.
SAFETY INSTRUMENTATION
(course code: 18 EI 7 F1)
Local Elective Course
[Oct ‘22 – Jan ‘23]
EIE Dept., RVCE.
Course Coordinator: Prof. S.V.

2.
INTRODUCTION TO: SAFETY TERMINOLOGIES
1. WHAT DO YOU MEAN BY THE TERM, “SAFETY”?
See: Video-1a & 1b.
What Does Industrial Safety Mean?
As the name suggests, industrial safety refers to the safety
management practices that apply to the industrial sector.
Those processes aim to protect industrial workers, machinery, facilities,
structures, and the environment.

3.
Industrial Safety Objectives:
1. Preventing work-related fatalities, disabling injuries, illness, and damage to
machinery or materials.
1. To achieve a safe and accident-free workplace.
1. To reduce the business’s cost to accident compensation and insurance claims
related to workplace accidents.
1. To ensure a high-morale work environment for a safer and smoother productivity.
1. To have competent supervision on the workers to maximize protection.
1. Ensuring continued production by preventing disruptive incidents.

4.
2. What is the difference between: “Safety” and “Protection”?
Pls. find it out yourselves.

5.
3. What is the difference between: “INCIDENT” & “ACCIDENT”?
- Ex: an “incidence of FIRE” vs. “FIRE Accident” - Difference?
- See – Video -5

6.
4. What is the difference between: RISK & HAZARD?
- See Videos – 2, & 3.

7.
5. What is a RISK MATRIX ?
- See Video - 4.

8.
Process Safety – Definition:
• A disciplined framework for managing the integrity of operating systems and
processes handling hazardous substances, by applying good design principles,
emergency engineering, and operating practices.
• Note: Process Safety focuses on efforts to reduce process safety Risks associated
with processes handling hazardous materials and energies.
• Process Safety efforts help to reduce the frequency and consequences of potential
incidents.
• These incidents include toxic or flammable material releases (loss events), resulting
in toxic effects, fires, or explosions.
• The incident impact includes harm to people (injuries, fatalities), harm to the
environment, property damage, production losses, and adverse business publicity.

9.
WHAT is a “SAFETY Instrumented system (SIS)”?
- Ref. to: Video-7

10.
•Industrial Accident – Youtube Videos
1. Mega Disasters Bhopal Nightmare
• https://www.youtube.com/watch?v=zcv2PrhUZ3A
2. Mixed Connection, Toxic Result
• https://www.youtube.com/watch?v=Tflm9mttAAI
3. Falling Through the Cracks
• https://www.youtube.com/watch?v=uo7H_ILs1qc
4. Behind the Curve
• https://www.youtube.com/watch?v=OCfNau54h6I
5. Filling Blind
• https://www.youtube.com/watch?v=41QMaJqxqIo

11.
“DISASTERS Analysis”
• ANSWER the following QUESTIONS to ANALYZE each DISASTER :
1. Name of the company where accident happened?
2. What was being produced in the industry?
3.
What is the incident that led to the disaster?
4.
What actually happened?
5.
Nearly how many people died, & how many injured, and how many were affected?
6.
What may be the cause of the accident? Weather it is the: a. leakage of poisonous gases like ammonia / Phosgene /
MIC, or massive cracks in concrete tanks, or occurrence of fire, or explosion, or chemical spill, or radiation leak, or due
to simple human negligence/ is it a Bad Maintenance Issue?
7.
Which Instrument/ Detector / SENSOR was involved to indicate a high pressure or gas leakage?
8.
How the disaster could have been prevented?
9.
WERE THE REQUIRED SAFETY MEASURES TAKEN BY THE INDUSTRY?
10.
WHAT MEASURES DO YOU SUGGEST TO PREVENT SUCH ACCIDENTS OR DISASTERS OCCURRING IN FUTURE?
11.
What SAFETY “Standards” need to be followed for the purpose of prevention and safe operations?

12.
Fire Triangle:

13.
Videos:
• What is a Fire Alarm System? - https://www.youtube.com/watch?v=cVjyDgFrb2g
• Fire Sprinkler Systems Explained - https://www.youtube.com/watch?v=o-ylvugYc0w
• GOOD - How to Install Smoke and Carbon Monoxide Detectors | Ask This Old House - https://www.youtube.com/watch?v=ScnFObV156c
• What Type Of Smoke Alarm Is Best For Your Home? - https://www.youtube.com/watch?v=J9zEi1otL88
• How to Safely Put Out a Kitchen Fire - https://www.youtube.com/watch?v=AFwkGTEles8

14.
The Fire Triangle
• The fire triangle or combustion triangle is a simple model, from the
science of firefighting, for understanding the ingredients necessary
for most fires. It has largely been replaced in the industry by the fire
tetrahedron, which provides a more complete model, also described
later.
• The triangle illustrates the rule that in order to ignite and burn, a fire
requires three elements heat, fuel, and oxygen. The fire is prevented
or extinguished by removing any one of them.
• A fire naturally occurs when the elements are combined in the right
mixture (e.g., more heat needed for igniting some fuels, unless there
is concentrated oxygen).

15.
The Triangle

16.
The Fire tetrahedron
• The fire triangle is a useful teaching tool, but fails to
identify the fourth essential element of fire: the
sustaining chemical reaction.
• This has led to development of the fire tetrahedron: a
triangular pyramid having four sides (including the
bottom).
• In most fires, it does not matter which element gets
removed; the fire fails to ignite, or it goes out. However,
there are certain chemical fires where knowing only the
fire triangle is not good enough.

17.
The tetrahedron

18.
How the Tetrahedron can help?
• Combustion is the chemical reaction that feeds a fire more heat and
allows it to continue.
• With most types of fires, the old fire triangle model works well enough,
but when the fire involves burning metals (known as a class-D fire in
the American system of fire classifications, involving metals like sodium,
lithium, magnesium, etc.), it becomes useful to consider the chemistry
of combustion.
• Putting water on such a fire could result in the fire getting hotter (or
even exploding) because such metals can react with water in an
exothermic reaction to produce flammable hydrogen gas.
• Therefore, other specialized chemicals must typically be used to break
the chain reaction of metallic combustion and stop the fire.

19.
Fire control: -
• Fire control consists of depriving a fire of fuel, oxygen, or heat
(see fire triangle) to prevent it from spreading or to put it out
entirely.
• The standard and most common way to control a class-A fire
(the combustion of a flammable material with oxygen and heat)
is to remove heat by spraying the burning solid fuels with water
from a fire-hose connected to a pump.
• Other methods of controlling a class-A fire would be to
"smother" the fire with carbon dioxide, such as from a fire
extinguisher, cutting off it's oxygen. In a forest fire, fire control
would usually consist of removing fuel in the fire's path and
digging trenches - this prevents the fire from gaining new fuel
and spreading.

20.
Classes of Fires: -
1. class-A fires
2. class-B fires
3. class-C fires
4. class-D fires
5. class-K fires

21.
Class A fire:
• Class-A fires are the most common type of fire, that occurs when a material such as wood or other fiber
becomes sufficiently hot, and has oxygen available to it, causing combustion. (See fire triangle) At this
point the material bursts into flame, and will continue burning as long as the fire triangle (heat, fuel, and
oxygen) continues to be available to it.
• Class-A fires are used all around buildings and everywhere in the world in controlled circumstances, such
as a campfire, lighter, match, or candle. This makes an example easy to come by. For example, a
campfire has a fire triangle - the heat is provided by another fire (such as a match or lighter), the fuel is the
wood, and the oxygen is naturally available in the open-air environment of a forest. This fire is not
dangerous, because the fire is contained to the wood alone and is usually isolated from the ground by
rocks.
• However, when a class-A fire burns in an environment where fuel and oxygen are in accessible positions,
the fire can quickly grow out of control; this is the case where firefighting and fire control techniques are
required.Class-A fires are fairly simple to fight and contain - by simply removing the heat or oxygen (or in
some cases fuel), the fire triangle collapses and the fire dies out.
• The most common way to do this is by removing the heat by spraying the fire with water.
• Other means of control or containment would be to "smother" the fire with carbon dioxide or nitrogen from
a fire extinguisher, cutting off its oxygen and causing the fire to die.
• Class-A fires are the most commonly encountered fires, and as such most fire departments have

22.
Fire Extinguisher types -ABC
• 1.ABC Dry Chemical:
• These are found in sizes containing from 5 to 20
pounds of monoammonium phosphate.
Monoammonium phosphate is a finely ground
extinguishing agent, which looks like yellow talcum
powder. Nitrogen gas is used for propellant.
• This extinguisher is particularly effective on class
A, B, and C fires but is also extremely messy.
• Operation is fairly simple. Pull the pin through the seal,
aim the exinguisher at the base of the fire and sweep
from side to side. The extinguisher has a range of
about 15 feet.
•
• These extinguishers are found in hallways and
occasionally in labs.

23.
Class B: -
• Class-B fires are combustible fuels.
• These fires follow the same basic fire triangle (heat, fuel, and
oxygen) as class-A fires, except that the fuel in question is a
solvent (liquid).

24.
Fighting a Class “B” fire: -
• Class-B fires (hydrocarbons and fuels on fire) require much different handling than the
standard water approach.
• Many fuels, such as gasoline or oil float on water, and water would actually end up
spreading the fire further.
• Other fuels, such as coal, will not be put out by water, as fire spreads to the inside of
the coal and cannot be reached by water - as soon as the water stops, the fire inside of
the coal spreads back out to the outside.
• Fire control of these fires requires specialized methods, and can be problematic to
ordinary fire stations due to the fact that these materials may not always be available.
• One way to control a class-B fire would be to dump chemical dust on it - this is also
a method for handling class-A fires, and actually tends to be preferable due to the fact
that sprayed water tends to cause property damage.
• Gasoline fires are more often smothered in a cooling protein foam.

25.
Class “C” fire: -
• Class-C fires are electrical fires, where the heat side of the fire triangle
is caused by, for example, short-circuiting machinery or overloaded
electrical outlets.
• These fires can be a severe hazard to firefighters using water: when the
solid stream of water hits the electrical fire, the electricity is conducted
through it and into the hose, then into the firefighter's body. Electrical
shocks have caused many firefighter deaths.
• There are two main ways of fighting a class-C fire: cutting off its oxygen,
or simply turning off the electricity to the fire from a breaker.
• A class-C fire can be put out with a fire extinguisher rated for class-C
fires, or with protein foam, but the primary approach is to simply turn off
the power as noted above. This causes the fire to become an ordinary
class-A fire, or perhaps to die out entirely.

26.
Fighting a Class “C” fire
• Class-C fires are electrical fires - fires that are
caused by an electrical source and get their
heat from electricity.
• These fires are dangerous because if water is
used on them, electrical current will be passed
through the stream and back into the
firefighter.
• There are only two ways to deal with this type
of fire - take away the oxygen (smother it with
foam or a fire extinguisher) or simply turn off
the electricity, which will cause the fire to
either die out or become a regular class-A fire.

27.
Fire Extinguisher types -C02
• 2.Carbon Dioxide: This is a high
pressure vessel filled with either 5
or 10 pounds of liquid CO2.
• It is only to be used on flammable
liquid or electrical fires.
• Because the CO2 is expelled as a
gas the extinguisher has a very
limited operation range of about 4
to 6 feet.
• This extinguisher is found mostly in
labs or mechanical rooms. The
carbon dioxide extinguisher can be
easily identified because it does not
have a pressure gauge.

28.
Halon
• 3.Halon: A halon fire extinguisher uses
bromochlorodifluoromethane, halon 1211,
as its extinguishing agent.
• Halon is an extremely clean agent leaving
no residue. This makes it a good agent for
use around computers and other sensitive
equipment.
• Range is about 15 feet. Pull the pin, aim at
the base of the fire and sweep from side to
side. Operation is similar to the ABC
extinguisher.

29.
Class D fires
• Class-D fires are metal fires. Certain metals, such as sodium, titanium,
magnesium, potassium, uranium, lithium, plutonium, calcium and others are
flammable. Magnesium and titanium fires are common.
• When one of these combustible metals ignites, it can easily and rapidly spread to
surrounding class-A materials.
• Generally, masses of combustible metals do not represent unusual fire risks
because they have the ability to conduct heat away from hot spots so efficiently
that the heat of combustion cannot be maintained - this means that it will require a
lot of heat to ignite a mass of combustible metal.
• Generally, metal fire risks exist when sawdust, machine shavings and other metal
'fines' are present. Generally, these fines can be ignited by the same types of
ignition sources that would start other common fires.

30.
Fighting Class “D” fires
• Water and other common firefighting materials can excite metal fires and make
them worse.
• The NFPA recommends that class D fires be fought with 'dry powder' extinguishing
agents. Dry Powder agents work by smothering and heat absorption. The most
common of these agents are sodium chloride granules and graphite powder. In
recent years powdered copper has also come into use.
• Some extinguishers use dry chemical extinguishing agents. This is easily
confusable with dry powder. They are quite different, and using one of these
extinguishers in error in place of dry powder can actually increase the size of a
class D fire much like water.Class-D fires represent a unique hazard because
people are often not aware of the characteristics of these fires and are not
properly prepared to fight them.
• Even a small class-D fire can spread class-A fires to the surrounding combustible
materials. Most fire stations do not have class-D extinguishing agents available to
them, making fighting these fires a logistical problem - however, most places
where these materials are found there is a hopper filled with the proper
extinguishing agent.

31.
Dry Powder for Class “D”
• Dry Powder: These extinguishers are for use on metal
fires. Extinguishment is achieved by isolating and
smothering the fire with either a graphite or sodium
chloride based powder.
• Some of these extinguishers are cartridge operated, so
they are a little different to use: before the agent can be
released a plunger on the side of the extinguisher must be
pushed down to charge the extinguisher with propellant.
• Once charged, the operator depresses the handle at the
nozzle and lets the powder flow over the fire. Range is
about 1 to 2 feet
• The newer dry powder extinguishers are mounted on 2
wheel carts. Operation is similar to ABC, Halon and
Carbon Dioxide extinguishers. Pull pin, take the hose and
wand assembly out of the retainer and aim at base of the
fire. Range is 3 to 6 feet.

32.
Class “K” fires: -
•Class-K fires are fires that involve cooking
oils.
•Though by definition Class-K is a subclass of
Class-B, the special characteristics of these
types of fires are considered important enough
to recognize.

33.
Class K Fire Extinguishers
• In recent years there has been a trend for commercial
kitchens to start using much more efficient cooking
appliances and unsaturated cooking oils that operate
at much higher temps than the previous oils and
appliances. The class K extinguisher was developed
to combat this new hazard.
• This extinguisher uses a wet potassium acetate based,
low pH agent that has a greater fire fighting and
cooling effect for this type of hazard.
• Most of these extinguishers can safely be used on
Class A, B, and C fires also.
• Their range is 10-12 feet and will last for about 40
seconds. Once again break the seal pull the pin and
aim at the base of the fire. Class K extinguishers
can be found in kitchens on campus.

34.
When and How to fight a fire
• Before deciding to fight a fire, be certain that:
• The fire is small and not spreading. A fire can double in size within two
or three minutes.
• You have the proper fire extinguisher for what is burning.
• The fire won't block your exit if you can't control it. A good way to
ensure this is to keep the exit at your back.
• You know your fire extinguisher works. Inspect extinguishers once a
month for dents, leaks or other signs of damage. Assure the pressure is
at the recommended level. On extinguishers equipped with a gauge, the
needle should be in the green zone - not too high and not too low.
• You know how to use your fire extinguisher. There's not enough time to
read instructions when a fire occurs.

35.
Then Fight the Fire Safely:
• Stand with an exit at your back.
• Stand several feet away from the fire, moving closer once the fire starts to
diminish.
• Use a sweeping motion and aim at the base of the fire.
• If possible, use a "buddy system" to have someone back you up or call for help
if something goes wrong.
• Be sure to watch the area for awhile to ensure it doesn't re-ignite.

36.
Never Fight A Fire If:
• ･The fire is spreading rapidly. Only use a fire extinguisher when
the fire is in its early stages. If the fire is already spreading
quickly, evacuate and call the fire department.
• You don't know what is burning. Unless you know what is
burning, you won't know what type of fire extinguisher to use.
Even if you have an ABC extinguisher, there could be
something that will explode or produce highly toxic smoke.
• You don't have the proper fire extinguisher. The wrong type of
extinguisher can be dangerous or life-threatening.
• There is too much smoke or you are at risk of inhaling smoke.
Seven out of ten fire-related deaths occur from breathing
poisonous gases produced by the fire.

37.
Using A Fire Extinguisher
P A S S
•Pull the Pin at the top of the extinguisher. The pin releases a locking mechanism and
will allow you to discharge the extinguisher.
•Aim at the base of the fire, not the flames. This is important - in order to put out the
fire, you must extinguish the fuel.
•Squeeze the lever slowly. This will release the extinguishing agent in the
extinguisher. If the handle is released, the discharge will stop.
•Sweep from side to side. Using a sweeping motion, move the fire extinguisher back
and forth until the fire is completely out. Operate the extinguisher from a safe
distance, several feet away, and then move towards the fire once it starts to diminish.
Be sure to read the instructions on your fire extinguisher - different fire
extinguishers recommend operating them from different distances.
•Remember: Aim at the base of the fire, not at the flames!!!!

38.
Stop, Drop, and Roll

39.
Fire will Produce:
•Any sort of fire will produce some amount of carbon
monoxide, the most deadly gas produced by a fire.
•Materials such as wool, silk, nylon and some plastics
can produce other highly toxic gases such as
carbon dioxide, hydrogen cyanide, or hydrogen
chloride.
•Beware - all of these gases can be fatal!
•Smoke inhalation or exposure to fire itself can be life
threatening so get educated about the basics in CPR and
burn treatment.

40.
• A typical fire extinguisher contains 10 seconds of extinguishing power.
• This could be less if it has already been partially discharged.
• Always read the instructions that come with the fire extinguisher beforehand and
become familiarized with its parts.
• It is highly recommended by fire prevention experts that you get hands-on
training before operating a fire extinguisher.
• Most local fire departments offer this service.
• Once the fire is out, don't walk away! Watch the area for a few minutes
in case it re-ignites.
• Get the extinguisher recharged immediately after use - check that this
has been done as You may have to use it again.
Remember:

41.
When in doubt, get out!
• If you use a fire extinguisher, notify Mr. Holter and the
nurse immediately!
• Environmental Health and Safety will have to be notified
soon as possible.
• Never remount an extinguisher after use - set it aside
in a space where it can be seen.
• Remember: When in doubt, get out!!!!!

42.
Standards and Regulations: -
1. A "Standard" is a mandate that one has to follow.
2. "Regulation" is a guideline that one may use it.
3. Ex-1: European union was formed to ensure medical equipments are in conformance with
certain medical Standards.
4. : Any car must follow European union Standard diagnostic tools, and it is a regulation.
5. REGULATION can be met using different standards.
6. EMC compliance is a Standard.
7. REGULATION says that get a certificate which is authorised by any standard third party agencies and it
should be unbiased.
8. A “STANDARD” IS A BEST PRACTICE.
9. A “REGULATION” IS A LAW OF THE LAND.
10. You have to be safe to be fine.
11. So, to feel fine, and be safe, one has to be aware of and follow the norms of the Standards and
stipulations of the Regulations.

43.
- Types of Fire Extinguisher and Their Uses - www.youtube.com/watch?v=GjSoxJF3RD4