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lm Oil Mills Loss Prevention

ZARDOUS AREAS IN PALM OIL MILLS

Loading Bay

ring low crop season the Fresh Fruit bunches may be left at the loading bay

a long time before they are being transferred to the steriliser. The

umulation of palm fruits here increases the risk of spontaneous combustion.

Fruit Elevator

er sterilising the palm fruits are warm and oily. As the fruits are transferred by

t elevator (in some mills only), any contact of additional heats may cause a

inside the fruit elevator. A fire in the fruit elevator is difficult to control

cause it is partly covered and it could spread to the rest of the production

e. The additional heat could be a result of hotwork done for maintenance or

air at a location near the fruit elevator.

Depericarper

its from the pressor are transferred into the depericarper after most of the oil

obtained. The depericarper separates the fruit into fibres and kernel. A fire

n occur here because there are fuel (dry fibres), oxygen (air required to blow

res to boiler) and heat source (generated by the depericarper machines).

Kernel silo

e kernel silo area is hazardous due to its oil content and temperature. Fire can

ignited spontaneously inside the silo if the kernels are kept there longer than

hould. The fire hazards are increased as the fuel, oxygen and heat are all

de the silo making fire fighting more difficult to handle.

Excess fibres

metimes (in some mills) there will be excess fibres not required by the boiler.

e excess fibres are usually dry and easily combustible. Accumulation of such

ste within the production building increases the risk of fire. When the excess

res are on fire, they are also possible to spread fire because they can be

wn by wind to other areas.

SS PREVENTION MEASURE FOR PALM OIL MILLSFire Fighting Team

Under the Occupational Safety and Health Act and Regulations (Act 514), it

states that every employer has the duty to ensure the safety, health and

welfare at work of all his employees, so as far as is practicable.

In the process of achieving the above obligation, it further states under the

Act that for an organisation of more than forty (40) people employed, the

employer shall establish a safety and health committee at the workplace. One

of the functions of the committee is to keep under review measures taken to

ensure safety and health of persons at workplace.

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The committee shall look into all safety aspects within the organisation,

covering all areas from the main operation area to even the office area. Fire

safety is one of the vital safety aspects that has to be covered by the

committee. It is strongly recommended that another committee be formed to

handle this matter known as fire fighting team.

In the fire fighting team, there should be at least 8 (eight) persons per shift

fully trained in all aspects of fire fighting. In the event of a fire, this team

should co-ordinate to :

1. Raise the alarm or siren (has to be installed if there is none on site)2. Call the fire brigade

3. Monitor workers evacuation

4. Fight the fire with the readily usable fire fighting appliances available in

the mill.

The other functions of the fire fighting team shall be:

1. To ensure all fire safety regulations at workplace are strictly complied with.

2. To ensure all the fire fighting equipment are well maintained and in good

working condition at all times

3. Liaison with Bomba to conduct fire drills for the mill employees at least

twice a year.

It would be very necessary to have a fully trained and competent fire fighting

team for the following reasons appended below :-

Due to the remoteness of the mill, in the event a fire occurs, it may be

too late by the time the nearest fire brigade response to render

assistance.

By having a fully organised fire fighting team is very useful to prevent

further damages either to life or property in the event of a fire.

As the first five (5) to ten (10) minutes are the most critical, a quick

and effective response by the fire team can at the very least minimise

the loss.

Fire Fighting Equipment

(i) Hand Fire Extinguishers

Hand fire extinguisher is the most portable fire fighting facility that a fully

trained in-house fire fighting personnel can use to attack a fire at the early

stage.

For every 2,250 square feet, there should be at least one (1) 9 kg dry powder

hand fire extinguisher or four (4) 2.27 kg carbon dioxide hand fire

extinguishers. In the boiler room and for all electrical appliances, 2.27 kg

carbon dioxide hand fire extinguishers should be provided.

All the extinguishers should be kept either mounted on brackets or in a

prominent position and should be serviced annually by a reputable fire

contractor.

(ii) Hydraulic Hose Reels

Hydraulic hose reel is an active protection system where its usage is for a

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fully trained in-house fire fighting personnel to attack a fire while awaiting for

Bomba to render services. The system should not be used other than for fire

fighting purpose. Please refer to the attached sheet for specification.

At least once a week, the system should be tested to ensure it is in good

working condition and whatever problems encountered should be rectified as

soon as possible.

(iii) Hydrants and Canvas Hoses

Hydrant is an active protection system which normally used by Bombapersonnel to fight a fire. In spite of that, it can also be used by fully trained

n-house fire fighting personnel.

Similar to hose reels, the system should not be used other than for fire

fighting purpose. Please refer to the attached sheet for specification.

(iv) Water Drencher System

The nut silo, palm kernel silo, digester, screw press and the fruit elevator

should be fitted with a water drencher system to prevent spontaneous

combustion (if the mill does not already have one installed) as these are

critical areas to the operation of the palm oil mill.

In the warehouse area, it would be necessary to maintain good housekeeping

practises coupled with proper storage arrangements.

No Smoking Rule

The No Smoking rule should be strictly enforced by the mill management

throughout the entire mill. Smoking should strictly be allowed only at

designated smoking areas e.g. canteen. Employees caught smoking should be

given a stern warning and for second time offenders, dismissal should be

considered.

Hot Work Permit

All the hot process inside the premises (e.g. cutting, welding etc.) should only

be conducted with a Hot Work Permit Scheme implemented. With the Hot

work Scheme, no employee or outside contractor may start any hot work

operations until he has obtained a permit from the factory manager or safety

officer. The permit is a means of ensuring that :-

(i) The area is made as safe as possible before any hot work begins

(ii) Precautions are taken while the work is in progress(iii) The area is checked afterwards

A copy of the publication by the Fire Prevention Association of UK on the

needs and practice of this scheme is enclosed for your attention and

appropriate action.

Security Guards

The security guards must be provided with a telephone in the guard house in

order to make a call to the fire brigade in an emergency. Patrol clocking

stations should be fitted around the premises perimeter so that the security

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guards patrol the premises at regular intervals, especially at night. Further, all

the security guards should be part of the fire fighting team and they should

be given formal training with fire drills conducted at least twice a year.

Housekeeping (Workshop & Store)

The workshop and store are areas where good housekeeping procedures need

to be implemented. These would be :-

All oxy-acetylene and other gas cylinders are chained within a confined

area to prevent the cylinders from toppling.Ensuring all oil containers (including empty drums) are always kept closed

with the lids screwed on. This is because if left open, flammable vapours

may disperse in the air and if it comes into contact with an ignition source,

an explosion may result.

All oil leaks should be cleaned and the rags used to clean it should not be

left lying around. Either they should be disposed into metal bins with self

closing lids or the rags should be kept soaked within a small container with

water at all times.

All the electrical wiring should either be carried in metal trays or metal

conduits. It is vital that all welding and cutting is not done in the vicinity

of power points with electrical wires dangling loosely without any

protection.

Under no circumstances should workers be allowed to smoke inside the

workshop. No Smoking signs should be put at the entrance with regular

checks conducted by the supervisor.

Bunding of Diesel Storage Tanks

Ideally, the diesel skid tank(s) should be enclosed within a bund wall that canabsorb a spill up to 110% by volume of the largest skid tank within the wall.

Alternatively, the diesel skid tanks should be bunded with a one (1) foot high

cement wall on three (3) sides, designed with an incline of 30. This will

enable any spillage to be confined within the bund and the 30 incline will

prevent diesel seeping out from the open side of the bund wall. The open side

of the bund wall will facilitate movement of the skid tank into and out of the

bund wall without breaking the wall.

Protection for kernel silos

The kernel silo where kernels are temporary kept before packing is considered

a high risk area within the palm oil mill. Smouldering of kernel have been

reported frequently and damage to silos are also possible. A standard

approach to minimise this occurrence is by installing a drencher at the top of

the silo. A drencher or sometimes called a wet riser consists of piping system

with a manual valve to allow water to cool down the kernel inside the silo. It

s also important that the valve for the system is located away from the silo

tself.

A man-hole can be installed at the bottom of the silo. During an emergency,

the man-hole can be opened quickly allowing kernel to drop onto the ground,

thus allow fire fighting by portable fire extinguishers or hose reel.

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Kernel silos or silos in general can also have temperature probe installed to

monitor temperature inside the silo.

Protection to weighbridge

The weighing cell at weighbridge is sensitive to lightning damage. Apart from

using lightning arrestor and surge protector, other recommendations which

have been practiced by some palm oil mills are :

a) constructing a shed over the weighbridge areab) changing pit type weighbridge to 1 foot elevated weighbridge

c) manual weighing when there is a thunder storm

d) using surge protector for both ends of cable connecting computer and

weigh cells

e) separate earthing for lightning arrestors and electricals

Note: Lightning arrestors are normally protecting building only but not the

sensitive electricals inside.

ECIFICATIONS

draulic Hose Reels

ses for the hydraulic hose reels must be of reinforced rubber lined hoses of

t less than three quarter () inch nor more than one and a quarter (1) inch

ernal diameter. The rubber hoses must not exceed one hundred and fourty

ht (148) feet in length and be fitted with nozzles of not more than one

arter () inch internal diameter.

ote : The above stated one quarter () inch nozzle requirement may be

itted where combination jet/spray nozzles are fitted and provided the jet is

pable of reaching not less than twenty (20) feet)

e number and distribution shall be such that the whole of each building is

tec ted and that no part of the floor is more than twenty (20) feet distant

m a hose nozzle when the hose is fully extended. Ideally, there should be four

hose reel points installed at all the four (4) corners of the mill.

e hose reels system must be permanently connected to an adequate constant

pply of water of 800 gallons (3,640 litres). Water supply should be boosted by

tionary pumps to ensure there is adequate water pressure in the system. The

tionary pumps must be capable to discharge water at 20 gallons per minute

ough the nozzle.

drants and Canvas Hoses

ere should be at least one (1) hydrant for each 250 feet of external wall

asurement and the hydrant should not be located more than 75 feet away

m the building. For every two (2) hydrants, there should be provided at least

e hundred (100) feet of hose and fixed jet/spray nozzles, kept under cover in

rpose built cabinets located in convenient places.

e hydrant mains and hoses must have a clear waterway of at least two and a

f (2) inches in diameter. The hydrant system must be fed from an

ependent water supply having a minimum capacity of 12,000 gallons (54,560

es) with manual or automatic pumps. Each pump shall be capable of

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charging at a rate of not less than 200 gallons per minute (900 liters per

nute) to the highest point of the protected premises. Alternatively, the

drant system shall be permanently connected to an adequate constant water

pply from the public mains.

ote : Where Stationery Fire Pumps are provided to ensure the requisite

ssure, they must comply with the under noted requirements).

ationary Fire Pumps - Requirements

The appliances must always be available on the premisesEach pump must be housed in an easily accessible position where it will not

be liable to be damaged by fire or otherwise

There must be kept on hand at all times sufficient fuel to run all the pumps

at full load for not less than twelve (12) hours and power must always be

available for each pump