Risk Engineering Services

Flammable and combustible liquids

Mixing operations

The use of flammable and combustible liquids is common in the manufacturing processes
of items such as paints, cosmetics, personal care and cleaning products, as well as
pharmaceuticals, among others. Due to the fire and explosion hazards associated with
these materials, a number of measures should be considered to help prevent or control
incidents that could result in extensive property damage and production downtime.
Are your plants protected?

The fire hazard involving flammable In addition to fire, flammable and Due to the fire and explosion hazards,
and combustible liquids arises from combustible liquids may also create the handling of flammable liquids
vapors emanating from the surface an explosion hazard. For this to occur, used in industrial processes requires
of these substances. When the all the following conditions must exist: a high level of care. The same applies
temperature of a flammable or (1) accumulation of flammable liquid to combustible liquids when heated
combustible liquid, whether the liquid vapors within a confined space, above their flash point, as they behave
is in a natural state (room temperature) (2) presence of an explosive mixture in the same way as flammable liquids.
or heated, reaches or exceeds its flash of flammable liquid vapors and air, and This is the case with heat transfer fluids*,
point, vapors evolved will have enough (3) an ignition source. for example.
concentration to ignite and burn,
causing a flash when exposed to In broad terms, NFPA 30 (flammable The prevention and protection
an ignition source. If the temperature and Combustible Liquids Code) defines measures indicated below are a useful
of the liquid is at or above its fire flammable liquids as those having a tool for companies to deal with the
point, then vapors, if ignited, will flash point below 100o F (37.8o C), and risks associated with processes and
sustain combustion. combustible liquids as those with a operations that involve the use of
flash point at or above 100o F (37.8o C). flammable liquids.

Throughout this document, the term

flammable liquid also refers to
Examples of flammable liquids Examples of combustible liquids combustible liquids heated above their
flash point. This guide does not apply
Acetone Hexane Essences Insulating mineral oil to processes and operations involving
Isopropyl Alcohol Methanol Fuel oil Corn oil chemical reactions, distillation, solvent
Benzine Methyl-Ethyl-Ketone Hydraulic oil Soybean oil extraction, refining or the manufacture
Ethanol Pentane Lubricants Organic heat transfer fluids* of petroleum-based products, in addition
Gasoline Toluene to the storage of flammable and
combustible liquids.
Prevention and protection In assessing room explosion hazard, of classes, divisions and zones as
measures the following should be considered: defined in Chapter 5 of NFPA
—— Usually flammable or combustible 70 – National Electrical Code.
Construction and location liquids heated above their
flashpoint, but below atmospheric ̤̤ Design, selection and installation
̤̤ Operations involving the use of boiling point pose more of a fire risk of electrical wiring and utilization
flammable liquids should take place than an explosion risk. equipment should meet the
in non-combustible buildings. —— For mixing facilities without requirements of NFPA 30 –
atmospheric distillation or vapor Flammable and Combustible
̤̤ For operations using amounts of phase organic heat transfer Liquids Code, Chapter 7.
flammable liquids which, if released systems, a full complement of
and ignited, could cause a substantial damage-limiting construction Static electricity – dissipation
amount of property damage, the (i.e. a combination of pressure through bonding and grounding
following should be considered: venting and pressure resistant
—— Process areas should be provided walls) is generally not necessary. ̤̤ Bonding is used to reduce the
with automatic sprinklers or water Ventilation should still be provided electrical potential difference
spray systems designed in as outlined. between conductive objects,
accordance with NFPA or even where the resulting system
equivalent standards. ̤̤ Buildings may require drainage to is not grounded. Grounding, on
—— If the above is not possible (ex. direct a flammable liquid spill or pool the other hand, equalizes the
a facility with no water supply) fire from a process area to a safe electrical potential difference
conduct operations in a reinforced location. Drainage systems should be between the object and the earth.
concrete building or protect designed to handle the anticipated
structural steel supporting the worst case release of material plus ̤̤ To avoid the accumulation of static
building structure and process the water needed for firefighting electricity generated in the handling
equipment with fireproofing. (automatic systems and hose and transfer of flammable liquids,
Fireproofing should be rated for streams). The need for drainage is all equipment should be reduced to
the hydrocarbon fire exposure. dependent on a number of factors. the same electrical potential through
—— Regardless of the chosen option, Liquids that are fully miscible in water, connection and grounding devices.
steel building columns or vessel heavier than water and/or have very
supports exposed to a flammable high flash points generally do not ̤̤ Grounding:
liquid fire need protection. require large drainage systems. —— All fixed equipment handling
flammable liquids should be
̤̤ Preferably, operations involving ̤̤ Means of containment should grounded through suitable
the use of flammable substances be provided to prevent spills from conductors, or metallic bond
should be carried out in a dedicated reaching adjacent aboveground/ wires. This includes mixing tanks,
building, isolated from other areas underground areas. Again, the vessels and containers, piping,
by a minimum distance separation expected amount of liquids release pumps and transfer mechanisms,
of 50 ft (15 m). and their characteristics will among others.
determine how much and where —— Grounding connections should
̤̤ If this is not feasible, isolation should containment is required. be provided for movable
be promoted between the operation equipment and containers,
involving flammable liquids and Classified electrical equipment such as portable tanks, or
any other operation or area through temporary IBC type storage
fire rated walls. ̤̤ Electrical equipment in process and transfer containers.
areas using flammable liquids should —— Containers made of non-
̤̤ An alternative to installing fire walls, be properly classified in order to conductive material or which
would be to enclose these operations avoid the possibility that they act do not allow for proper grounding,
in a fire rated vault with masonry walls as a source of heat / ignition. This should not be used in operations
and a concrete slab. includes lighting fixtures, switches, involving the handling and
power outlets, electric motors, transfer of flammable liquids.
̤̤ In either case, openings to adjacent electrical panels, data processing,
internal areas should be protected automation, instrumentation and ̤̤ Bonding. Any transfer of flammable
by self-closing fire doors. telecommunications systems. liquids between equipment and/or
If required, only classified forklifts containers that are not permanently
̤̤ Depending on the type of process should be used. The main concern installed and grounded, should only
and the volumes of flammable liquids is with processes in which flammable occur if there are means to promote
used, construction should be robust liquids are used in open or semi- the electrical grounding of at least
enough to withstand the pressures open systems. one of the pieces of equipment or
anticipated in the event of an containers involved and if both have
explosion. Alternatively, buildings ̤̤ An adequate classification of process been reduced to the same electrical
and structures should be fitted areas where flammable liquids are potential through connectors
with mechanisms to relieve the over- used should be carried out in or cables.
pressures resulting from an explosion. accordance with the designation
Ignition sources ̤̤ The exhaust fans should be interlocked —— Interlocking devices should be
with the electrical system in the area available to prevent overpressure
̤̤ Smoking should not be allowed in to prevent that process equipment or during pump transfer operations.
any area where flammable liquids lighting systems be energized without The relief mechanism should
are present. the exhaust system being in discharge any excess volume back
operation. If vapors are released to the suction tank, pump suction
̤̤ Avoid carrying out hot works in areas during idle periods, the exhaust intake or to a safe location.
involving the processing and handling system should be designed —— For manual transfer operations
of flammable substances. If possible, to operate continuously, and (by gravity), dead-man type valves
hot works should be carried out in monitoring should be provided with should be provided so that, when
isolated areas. If this is not feasible, visual and audible alarms connected released by the operator, the flow
hot work should only be allowed to a constantly attended location. is immediately interrupted. When
if all flammable contents have dispensing from a metal drum,
been removed, and after washing Equipment, transfer systems and a safety vent bung should be
containers and equipment to avoid process vessels provided on the larger of the two
the presence of any flammable drum openings.
residue. A formal permit to work ̤̤ Process equipment and vessels
procedure should be used to should be built to prevent ̤̤ Install pushbuttons to allow operators
authorize and monitor the execution unintentional leakage of liquids to command manual shutdown of
of any hot work. and vapors, or to minimize the transfer systems (pumps) in an
amount of liquids or vapors released, emergency. In order to provide quick
̤̤ Only spark-resistant tools should should a leak occur. In general, and safe access for operators, the
be used. systems and processes containing pushbuttons should be installed in
flammable liquids should be designed an accessible and isolated location.
Ventilation so that the liquids are kept as much Transfer systems should have
as possible in fully enclosed systems. interlocking so that the shutdown
̤̤ In process areas where flammable This is not always possible with can also take place whenever a fire
liquids are used in open or semi-open semi-open systems. protection system is activated,
systems, a mechanical room exhaust such as sprinklers or hoses.
system capable of providing a ̤̤ Equipment and piping should be
ventilation rate of 1 ft³/min per ft² built of materials compatible with ̤̤ Safety shutoff valves should be
(0.3 m³/min per m²) of floor area the substances being used in the provided in piping systems to stop
should be provided. process, but always seeking to use the flow of flammable liquids in the
materials resistant to fire and event of a fire or explosion. Valves
̤̤ The room exhaust system intakes mechanical damage, giving can be actuated automatically via
should be installed within 12in preference to the use of metal. fusible links and/or by means of
(0.3m) from the floor, as most vapors Avoid using containers, permanently interlocks with fire protection systems
emanating from flammable liquids or temporarily, made of plastic or such as sprinklers and hoses.
are denser than air and tend to any other combustible material. Additionally, means for safe manual
accumulate near the floor. actuation of shutoff valves by
̤̤ Where flexible parts are required, operators should be provided.
̤̤ It is also necessary to provide spot use reinforced rubber hoses or hoses The need for and number of safety
extraction points in order to remove covered in wire mesh. shutoff valves should be evaluated
vapors generated in process via a hazard analysis that determines
equipment containing flammables, ̤̤ For transfer operations, the following the worst credible case release
such as mixing tanks/vessels, or should be considered: scenario and the potential
immersion containers. The points —— Whenever possible, transfer of consequences. Safety shutoff valves
of extraction should be located at flammable liquids should take should generally be considered for
the top of such pieces of equipment place via pressurized systems the following locations:
or near the point from which liquids using positive displacement —— On the discharge of tanks installed
are transferred. Points of extraction automatic pumps or by appropriate internally or externally.
should be installed within a 5ft manual pumps. —— On the bottom piping off large
(1.5m) radius from each potential —— Transfer systems should have mixing tanks, before any pump.
vapor source. a mechanism that allows the —— At points of flammable liquids use,
operator to select the volume such as supply pipes to pieces of
̤̤ Exhaust ventilation discharge to be transferred before equipment or at dispensing points.
should be to a safe location outside activation. In this way, the —— At the entrance point to a building
the building. system automatically interrupts or room where flammable liquids
the transfer flow as soon as the are used.
pre-set volume is reached.
Fire protection Human element, management ̤̤ Establish specific emergency
programs and emergency response procedures to address cases
̤̤ Install automatic sprinklers designed involving the release and ignition
and installed in accordance with ̤̤ Maintain good housekeeping of flammable liquids. As a minimum,
NFPA 13 – Standard for the conditions, prohibiting any kind of procedures should contemplate,
Installation of Automatic Sprinklers, storage and the accumulation of the following points:
for Extra Hazard occupancies. combustible material in production —— Immediate notification to the
and processing areas that use fire department
̤̤ For operations where large amounts flammable liquids. This includes —— Activation of the plant emergency
of flammable solvents are used, such the storage of packaging materials organization
as paint manufacturing, consider or liquid or solid raw materials that —— Cut-off the flow of flammable
installing sprinklers in combination are flammable or combustible. liquids to the processing area
with foam. If flammable liquids are —— Early identification of firefighting
non-water miscible and lighter than ̤̤ Follow manufacturer’s guidelines methods considering available
water, foam-water protection may regarding maintenance and testing equipment and building layout
be critical if adequate drainage is procedures for process safety and —— Conducting annual drills to address
not or cannot be provided. In other protection systems and devices, all aspects of emergency response,
cases, adequate water protection in including, but not limited to: including operation of firefighting
combination with adequate drainage liquid level sensors, high pressure equipment, actuation of shutoff
OR foam-water protection AND sensors in pumping systems, valves, and proper shutting down
adequate containment may be automatic shutdown and liquid of equipment, amongst others.
necessary. Foam water systems flow cut-off interlocks, and manual
should be designed and installed shutdown systems.
in accordance with NFPA If you would like to find out more about
16-Standard for the Installation ̤̤ Implement a routine of periodic this or other technical matter associated
of Foam-Water Sprinkler and inspections to check the operating with loss prevention and control, contact
Foam-Water Spray Systems. status of liquid transfer systems. our Risk Engineering Services team.
Particular attention should be paid
̤̤ Sprinklers should be installed to avoid to hoses and connections. Any
shielding by building or equipment signs of wear or leakage should Technical references:
NFPA Fire Protection Handbook,
structural elements, or by equipment be corrected immediately.
6-12 Flammable and Combustible Liquids
itself, including vessels and piping. NFPA 30 – Flammable and Combustible
̤̤ Even in the absence of regulatory Liquids Code
̤̤ Provide adequate manual fire requirements, elements of Process NFPA 13 – Standard for the Installation
protection through hose connections Safety Management (PSM) should be of Sprinkler Systems
NFPA 70 – National Electrical Code
and fire extinguishers as required implemented to a fundamental level. NFPA 16 – Standard for the Installation
by the authority having jurisdiction. Key programs include: of Foam-Water Sprinkler and Foam-Water
—— Management of change Spray Systems
—— Hazard analysis/review
—— Process safety information
—— Regular operator training
—— Incident investigation

The CCPS (Center for Chemical

Process Safety) is a good resource
for additional information, including
publications and training courses.

The guidance contained in this document, in the opinion of Swiss Re Corporate Solutions, is sound, reasonable and may help to reduce the risk of property loss and
business interruption. Swiss Re Corporate Solutions does not warrant that all losses will be avoided or that all reasonable preventive measures have been taken if
advice in this document is followed. By sharing its opinion as to certain sound and reasonable practices, Swiss Re Corporate Solutions does not relieve the insured
of its own duties and obligations with respect to assessing and implementing loss prevention measures and Swiss Re Corporate Solutions disclaims any liability
as respects loss prevention.

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