- PURPOSE
This procedure is about selection, use, care, and maintenance of Flash Fire Protective Clothing (FFPC) used for protection against Industrial Flash Fires and Electrical Arc Flash Fires.
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Selection, Use, Care, and Maintenance of Flash Fire Protective Clothing (FFPC)
2.1 This procedure applies to all employees, contractors, temporary help, or vendors at Air Products’ facilities as well as employees and contractors working at customer and supplier sites.
- DEFINITIONS
3.1 Combustible Dust—Any finely divided solid material which presents a fire or explosion hazard when dispersed in air. Combustible dust concentrations are usually found during loading, unloading, or conveying coal, finely divided solid chemicals, fertilizers or other combustible materials. The explosion from these concentrations may occur when high amounts of static electricity accumulates at low humidity and causes a spark which ignites the combustible mixtures present in the air.
3.2 Flash Fire Protective Clothing (FFPC)—Flame resistant or flame retardant clothing meeting performance standards outlined in 5.1.
3.3 FFPC Work wear—routinely worn trousers, shirt or coverall type garments.
3.4 Flame resistant fabric—A fabric that does not support combustion or is self extinguishing in air after removal of an external source of ignition. The material fibers do not support combustion due to their chemical structure. These fibers do not need a chemical additive to provide flame resistance.
3.5 Flame retardant fabric—A fabric that requires a chemical additive during the manufacture of a garment to provide flame resistance in air.
3.6 Flammable gas—A gas which is flammable in a mixture of 13 percent or less by volume with air, or which has a flammable range with air which is wider than 12 percent, regardless of the lower limit.
3.7 Flammable liquid—A liquid having a flash point below 38°C (100°F) and having a vapor pressure not exceeding 1.8 kg/cm2 (25.3 psig) at 38°C (100°F).
3.8 Flash fire—A short duration fire caused by ignition of a flammable or combustible gas/liquid, oxygen, combustible dust, pyrophoric gas/liquid, reactive metal or an electrical fault or short circuit.
3.9 Fire fighter turnout gear—A flame resistant or retardant garment (coat, trousers, gloves, hood, helmet with visor, and boots) used by professional fire fighters designed to withstand a constant high thermal exposure.
3.10 Pyrophoric—A chemical or mixture that will ignite spontaneously in dry or moist air at or below 54.4°C or 130°F.
3.11 Reactive Metal—Certain combustible metals, such as magnesium, titanium, potassium and sodium as well as organometallic reagents such as alkyllithiums, Grignards and diethylzinc. These materials burn at high temperatures and give off sufficient oxygen to support combustion. They may react violently with water or other chemicals, and must be handled with care.
3.12 Undergarments—Clothing worn underneath a flame resistant or retardant garment, for example, work shirt/pants, underwear, shorts.
- SUMMARY
4.1 FFPC must comply with local or national regulatory requirements. FFPC may be constructed of either flame resistant fabric or flame retardant fabrics provided it meets the performance specifications defined in 5.1.
4.2 Site management (or designee) must conduct a workplace risk assessment to determine if there are any tasks or areas involving industrial flash fire or electric arc flash fire hazards requiring the use of FFPC. The results of this assessment should be included in the site’s PPE Matrix.
4.3 FFPC is required whenever workers are exposed to significant burn hazards due to the exposure to the potential for electric arc flash or flash fire.
4.4 FFPC shall be used properly in conjunction with outer garments constructed from flame resistant and non-flame resistant fabrics.
4.5 FFPC shall be properly laundered and maintained to ensure its protective qualities are maintained over its expected useful life.
4.6 FFPC purchased and used for employees must be capable of maintaining its flame resistant properties for the serviceable life of the product, as determined by the manufacturer, when available. When alternative fabrics must be used, due to the unavailability of garments manufactured to retain their flame resistant properties for the life of the garment, FFPC must be removed from service (retired) when it exceeds the manufacturer’s indicated service life, if any. Sites which use flame resistant garments with a finite service life, based on time or number of washings, must establish a program to ensure service life is not exceeded.
4.7 Personnel who are required to wear FFPC must be properly trained.
- PROCEDURE
5.1 Specification
5.1.1 FFPC must comply with local or national regulatory requirements. At a minimum, it shall comply with the national consensus standards listed below (or another regional comparable standard):
| Potential Exposure | Performance Standards |
| Industrial Flash Fire | National Fire Protection Association (NFPA) 2112 – Standard on Flame-Resistant Garments for protection of Industrial Personnel Against Flash Fire: 2007 Edition (US)3
EN 531:1995 – Protective clothing for industrial workers exposed to heat (Europe)2, superseded by: EN ISO 11612:2008 Protective clothing—Clothing to protect against heat and flame EN 533: Protective clothing—Protection against heat and flame – Limited flame spread materials and material assemblies (Europe)2, superseded by: EN ISO 14116:2008. Protective clothing—Protection against heat and flame—Limited flame spread materials, material assemblies and clothing |
| Electric Arc Flash Fire
1 |
NFPA 70 E – Standard for Electrical Safety Requirements for Employee Workplaces (US)
EN ISO 11612:2008 Protective clothing—Clothing to protect against heat and flame |
| High Visibility Outer Garments in Arc or Flash Fire Application | ANSI/ISEA – 107 (2010 edition) High-Visibility Safety Apparel and Headwear (US) |
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Where no regulations or consensus standards exist, any of the performance standards above shall be used, as appropriate, for the region or country.
Examples of some brands that meet the specifications are:
- Nomex
- Indura and Indura Ultrasoft
- Proban
5.1.2 FFPC may be constructed of either flame resistant fabric or flame retardant fabrics provided it meets the performance standard defined in 5.1.1.
5.1.3 FFPC purchased and used for employees must be capable of maintaining its flame resistant properties for the life of the product (regardless of the number of washings), as determined by the manufacturer.
5.1.4 FFPC used for industrial flash fire protection must be naturally static dissipating or laundered per manufacturer’s instructions to minimize static buildup.
5.1.5 FFPC used for electric arc flash fire protection must not have exposed, electrically conductive materials (static dissipating fibers, metal zippers, or snaps) on the surface of the garment when worn to operate, inspect or maintain electrical distribution equipment.
5.1.6 FFPC work wear shall be designed for, and used as, the outermost garment and shall provide full body coverage (that is, torso, long sleeves, and long pants [or coveralls]) except as otherwise specified in this procedure. (Refer to 5.3.3 for information where lab coats may be substituted.)
5.1.7 Garments must be clearly labeled indicating the approval of the garment against the required performance standard.
5.1.8 Insignias (for example, name or patch) and embroidering must be made of flame resistant or flame retardant material, when available to comply with the performance standards in 5.1.
5.1.9 FFPC or outer garments may include high visibility reflective striping, but the reflective material must be made of flame resistant or flame retardant material (that is, 3M Scotchlite).
5.2 Workplace Risk Assessment
5.2.1 Site management (or designee) must conduct a site assessment, in accordance with the requirements below, to determine if there are any tasks or areas involving industrial flash fire or electric arc flash fire requiring the use of FFPC.
- Results of the workplace risk assessment shall be included in the site’s PPE risk assessment process as required in 25-010506 “Personal Protective Equipment Overview”. This must give explicit requirements for limited exposure* to a non-electrical flash fire hazard. *Limited exposure is defined as equipment observation, laboratory operations, shift readings, and site tours of short duration. Refer to section 5.3.3 for details regarding Limited Exposure Protection.
5.2.2 Required Use
FFPC shall be worn for the following tasks, at a minimum, or when a specific risk assessment deems necessary, based on the risk of flash fire:
- Operating and maintaining flammable gas or liquid process equipment, for example, flammable processes, storage tank, vaporizer, pump, tube trailer, tankers, cylinder transfills, and gas cabinet.
- Operating, inspecting, or maintaining industrial electrical distribution equipment per 25-010520 “Electrical Safe Work Practices – Operations Level”.
- Operating or maintenance activities involving combustible dust where the accumulation of combustible dust presents a risk of flash fire.
- Emergency response involving flammable liquids or gases where risk of Flash Fire is the primary hazard. The decision for FFPC shall be risk based. (Fire fighter turnout gear is an acceptable alternative to FFPC during emergency response).
- Activities in and around air separation process equipment containing high pressure oxygen (greater than 1,000 psig (69 Bar) and 23.5% O2). Specifically:
- a perimeter around the high pressure reciprocating and centrifugal compressors, formed by the barrier and a minimum of 6 meters from the recycle, vent, and outlet block valve;
- a perimeter of 6 meters from the recycle and outlet block valve on the high pressure GOX backup system;
- a perimeter of 6 meters from the 2500 psig GOX bottle, including the let down station;
- a perimeter of 6 meters for high pressure GOX PIC vents, pipeline block valves, let down stations where > 1000 psig is on the high pressure side.
- Handling large, open containers of flammable liquids, for example, more than 1 gallon or 4 liters.
- Operating and maintaining pyrophoric gas or liquid process equipment, for example, pyrophoric processes, storage tank, pump, tube trailer, cylinder transfills, and gas cabinets.
- Handling or transferring of reactive metals, except in closed containers. See section 5.2.5 for guidance when conducting a specific risk assessment.
Hazardous (Classified – Electrical) areas should be reviewed against the criteria listed in 5.2.5 to determine if FFPC is required.
5.2.3 Exceptions
- Where the potential for flash fire has been eliminated via a Safety Work Permit.
- FFPC is not required to be worn for limited handling of small quantities of flammable gases or liquids (unless an area has been designated FFPC required for other reasons) such as:
- Lab samples and reagents, for example, less than 1 gallon or 4 liters.
- Single, non-pyrophoric, flammable gas cylinder change out at a point-of-use location. (For example, changing a hydrogen cylinder out on a hydrogen fill manifold does not fall within this exception; changing a fuel gas supply cylinder to an analyzer in an air separation plant would).
- Fueling of vehicles or equipment with gasoline, diesel fuel, CNG or LPG, using conventional fueling equipment. This includes activities such as fueling gasoline powered generators and lawn mowers using portable fuel cans or fueling vehicles at stationary or portable fuel pumps.
- Fueling of hydrogen powered vehicles or equipment under the conditions listed in Appendix A.
- Handling of closed, non-bulk flammable containers (drums, totes, cylinder, carboys, etc.) for storage or transportation purposes.
- FFPC is not required to be worn under circumstances where the only exposure to flammable process equipment is operating and maintaining utility equipment containing a flammable gas or liquid fuel or refrigerant, for example, natural gas or oil-fired utility boilers, heaters and chillers using flammable fuels or refrigerants such as natural gas, ammonia, or propane.
- FFPC is not required to be worn to operate or maintain boilers or gas turbines that are solely used to generate steam and or electricity where low pressure flammable gas (< 100 psig) is solely used as a fuel source and no additional processing of the flammable gas (such as compression) takes place that would pose a potential flammable gas leak hazard.
- FFPC is not required to be worn in non-process areas (locker, break or control rooms, offices) unless specified by local procedures due to site specific hazards.
- FFPC is not required to be worn in designated areas once the flammable process or equipment has been shut down, positively isolated from the source(s) of flammables, depressurized, purged with an inert gas or otherwise cleared of flammables, and verified to be clear of flammables. The application of exception is subject to local management discretion based on local conditions and policies.
- FFPC is not required to be worn when moving or transporting tube trailers, tankers or other bulk containers containing flammable liquids or gases unless the activity takes place in an area designated FFPC required for other reasons. Any activity involving operation or maintenance of the process parts of the container (valves, pumps, etc.) are not included in this exception.
5.2.4 Prohibited Use
FFPC shall not be used as a substitute for firefighter’s turnout gear.
5.2.5 FFPC Specific Risk Assessment
Where appropriate, a specific evaluation of the work environment to determine the requirement for the wearing of FFPC shall be based on the potential hazards that workers are exposed to as part of their work duties. Factors in determining if FFPC garments are required shall include, but not be limited to, the following:
- Proximity of the work to be performed to a hazard presenting a flash fire potential;
- The presence of flammable materials in the environment during process operations;
- The potential for the task being performed to increase the possibility of a flammable release; this could result from a mechanical failure such as a line breaking;
- Operating conditions of the process—that is, potential for flammable fumes or vapors, and so forth;
- The presence of engineering controls designed to reduce exposure to flammable materials present during normal operations;
- The quantity of flammable chemicals relative to their ability to generate a flash fire and endanger a person;
- Accident history.
Caution: FFPC is designed to protect against flash fire; it does not provide additional protection against fires involving oxygen saturated clothing. While FFPC may be worn during activities which may expose the user to oxygen saturation, it cannot be relied on to provide additional body protection in an atmosphere containing more than 23.5% oxygen. FFPC will burn at an accelerated rate, like most other fabrics, when it becomes oxygen saturated.
5.3 Proper Use
5.3.1 General Rules
- FFPC must be worn, cared for, and maintained, in accordance with the manufacturer’s instructions; including any warnings and limitations provided by the manufacturer.
- FFPC shall be worn as intended (that is, front fully closed; sleeves and cuffs worn down and secured).
- Outer garments worn on top of FFPC work wear must also meet the requirements of 5.1 unless specifically addressed otherwise in this document.
- FFPC must be removed from service (retired) when it exceeds the manufacturer’s indicated service life.
- Retired flame resistant FFPC garments must be destroyed or disposed of in a manner assuring that they will not be used for protection against flash fire.
5.3.2 Outer garments
- Outer garments, worn over top of FFPC, must be designed to protect against the primary hazard to which the person is exposed.
- Outer garments worn for rain, welding or hot work must be made of either man-made flame retardant/resistant materials or naturally flame retardant materials such as leather. This increases the protection afforded by FFPC. Synthetics or synthetic blends of outer garments will melt onto the FFPC, continue to burn, and may contribute to the severity of a burn injury during a flash fire.
- Standard industrial grade (for example, plastic or PVC) rainwear is not approved for use as rainwear over top of FFPC. The primary hazard, in this case, continues to be flash fire.
- High visibility work wear for use in an area where FFPC is mandated shall meet requirements in Table 5.1.1 and 25-010512 Protective Clothing.
- Cold/wet weather outerwear should not have less flash fire resistance that the required FFPC (otherwise it could contribute to the flame intensity and cause further injury). Outer Wear constructed of the same fabric and flash fire protection characters as the innerwear Flashfire protective clothing is permissible.
- Standard industrial grade disposable coveralls or clean room suits may not be worn over FFPC when FFPC is required. Disposable flame retardant/resistant coveralls and clean room suits (which may or may not meet all the performance requirements in 5.1) may be used for tasks requiring FFPC when operational or maintenance tasks may cause contamination (for example, oil, grease, paint, or rockwool) to the wearer’s FFPC or the operation requires a clean room suit.
- Disposable coveralls/suits must be worn in conjunction with the wearer’s primary FFPC unless the suit or coveralls meet or exceeds the performance standards listed in 5.1.
- Disposable coveralls/suits worn over FFPC (when FFPC is required) must be flame retardant (or resistant) and anti-static (or static dissipating). Refer to the manufacturer’s literature to verify the capabilities and limitations of the coveralls.
- Disposable coveralls/suits must not be laundered unless specifically authorized by the manufacturer.
- Flame retardant disposable coveralls should be discarded after one use since the history of the fabric’s protective quality cannot be assumed and build-up of grease and dirt over repeated use could compromise the protection to the wearer.
- Disposable coveralls/suits must be replaced if they are contaminated with flammable or combustible substances.
- Flame retardant or flame resistant chemical protective clothing is preferred when chemical protection is required in addition to flash fire protection. However, due to the unique nature of chemical hazards and technological limitations, FFPC rated chemical protective suits may not be available or practical for certain applications. As such:
- Standard industrial grade (for example, plastic, PVC, nylon, polyester) chemical protective clothing (for example, apron, Level A & B chemical suits) is approved for use as a primary outer garment during operational, maintenance, or emergency tasks that may pose a chemical exposure to the wearer.
- When wearing non-FFPC rated chemical protective clothing, where both a chemical exposure and flash fire potential exist, FFPC rated garments (that is, coveralls) must be worn underneath.
5.3.3 Lab coats
- Lab coats constructed of flame resistant or flame retardant fabrics similarly found in FFPC which is in compliance with the specifications listed in 5.1.1 (that is, Nomex, Proban, Indura, etc.) are permitted for limited exposure* to a non-electrical flash fire hazard in lieu of full body protection (ref. 5.1.5).
*Limited exposure is defined as equipment observation, laboratory operations, shift readings, and site tours of short duration.
- FFPC lab coats are not permitted for use by personnel when operating, inspecting, or maintaining industrial electrical distribution equipment.
5.3.4 Undergarments
- Undergarments providing coverage of the body equivalent to that afforded by T-shirt and shorts are encouraged to be worn under FFPC. This provides an additional layer of protection between the wearer’s skin and the FFPC in the event of a flash fire.
- FFPC manufacturers recommend cotton as the fabric of choice for undergarments, rather than synthetic materials which can melt.
5.3.5 Insect Repellents
Some insect repellants, including those with N, N-diethyl-M-tolumide (DEET) and Picaridin are flammable contaminants. Treating flame resistant fabrics with DEET and Picaridin will impact the flammability of the clothing and should be avoided regardless of brand.
- Avoid applying DEET or other flammable insect repellants to FR clothing.
- Workers can apply the insecticide permethrin to their FR clothing without destroying the clothing’s flame resistance.
- DEET mosquito repellant can be applied to the skin, following manufacturer’s recommendation. However, permethrin should only be applied directly to clothing or other fabrics and not to skin.
- The combination of DEET applied to the skin and permethrin applied to the clothing is an effective combination to prevent mosquito bites.
5.4 Care and Maintenance
5.4.1 Cleaning
- FFPC shall be kept clean and free of any contaminants, for example, paint, oil, grease, rock wool, to ensure maximum flame resistant qualities. When a garment is contaminated, it shall be laundered and then inspected to ensure that all contaminants were removed during the laundering process. If contamination is evident after laundering the garment shall be replaced.
- FFPC’s properties may be degraded by improper laundering. Laundering procedures must be used that follow manufacturers recommendations for a particular garment or fabric.
Note: Care must be taken to ensure the fabric’s manufacturer approves the use of fabric softener to reduce static. Some manufacturers may prohibit this practice or have specific techniques which must be followed (that is, do not use liquid fabric softener in the wash, but you may dry with one fabric softener sheet.)
- Written laundering procedures or guidelines must be obtained from the vendor or manufacturer and issued to the employees or commercial vendor responsible for laundering FFPC.
5.4.2 Maintenance
- Users must inspect their garments for damage, soiling or contamination after each use.
- Inspections must look at the overall condition of the garment including fabric damage, hardware (that is, zippers, snaps) damage, seam damage, contaminated fabric and any end of service life cycle (retirement) requirements.
- Any FFPC that has tears or holes will be returned to the FFPC distributor or their designated representative for repair or replacement. No attempt to repair FFPC shall be made by anyone other than the FFPC distributor or their designated representative. FFPC with tears or holes shall be repaired using flame resistant or retardant materials, for example, patches, thread.
Warning: Unauthorized or inappropriate repairs may affect the garment’s performance with respect to its qualification under the performance standards in 5.1.1.
5.5 Training
5.5.1 Affected persons must be informed of the requirements for using FFPC as described in 25-010506 “Personal Protective Equipment Overview” – Training. This includes informing users of the requirements to wear FFPC, its limitations, and appropriate care instructions.
- RELATED INFORMATION
6.1 Air Products EH&S Documents
25-010506 Personal Protective Equipment Overview
25-010512 Protective Clothing
⊕ 25-010519 Welding, Cutting and Brazing Safety
25–010520 Electrical Safe Work Practices – Operations Level
6.2 Additional Reference Standards
⊕ EN 1149-5 Protective clothing. Electrostatic properties. Material performance and design requirements
⊕ EN 61482-5 Live working. Protective clothing against the thermal hazards of an electric arc.
Test methods. Determination of arc protection class of material and clothing by using a constrained and directed arc (box test)
⊕ EN ISO 20471 (Formerly EN 471) High visibility clothing — Test methods and requirements
Appendix A
Exemption for Fueling Hydrogen Powered Vehicles and Equipment with Gaseous Hydrogen
The fueling of hydrogen powered vehicles with gaseous hydrogen does not require the use of FFPC if all of the conditions below are met.
- Dispensing pressure does not exceed 10,000 psig (700 bar).
- The hydrogen dispensing system has been reviewed and approved by Air Products GEG Advanced Systems Engineering, including the fueling area (forecourt).
- The nozzle and receptacle are certified by a third party to SAE J2600 and SAE J2799.
- Any given employee that fuels vehicles only occasionally. If any given employee or person fuels more than two vehicles per day, they are required to wear PPE including FFPC during fueling.
Note: Vehicle defueling, vehicle maintenance, fuel station maintenance, and fuel station start-up activities are not included in the scope of fueling hydrogen powered vehicles. FFPC requirements for these activities are to meet Section 5 of this document.
This exemption does NOT include fueling vehicles with liquid hydrogen.