Hazard Identification and Fire Risk Evaluation through Advanced Detection System Installations in LPG Bottling Plants

Abstract

Industrial facilities, particularly those handling Liquefied Petroleum Gas (LPG) and other volatile petrochemicals, are highly susceptible to catastrophic fire and explosion hazards. The rapid escalation and destructive totality of such incidents necessitate the deployment of robust and highly responsive active fire detection and alarm systems to mitigate risks to human life, property, and the environment. This dissertation comprehensively investigates the design, installation, and optimization of active fire and gas detection systems specifically tailored for LPG workplace environments, including bullet storage, Horton spheres, and mounded storage facilities. The primary objective is to formulate a cohesive safety framework that ensures rapid anomaly detection while significantly minimizing the occurrence of false alarms—a prevalent issue that severely compromises system credibility, increases operational costs, and induces organizational disruption. The study involves a detailed technical analysis of various detection methodologies, including ionization and optical smoke detectors, fixed-temperature and rate-of-rise heat detectors, multi-sensor systems, and infrared/ultraviolet flame detectors. A quantitative assessment is conducted to determine the optimal configuration, spacing, and siting of these sensors based on the specific geometry and hazard profile of different LPG storage vessels. The research highlights the strategic placement of heat detectors encircling storage vessels and gas detectors positioned near Remote Operated Valves (ROVs) and inspection tunnels to ensure maximum coverage and early warning capabilities. Furthermore, a detailed cost-estimation model for the complete installation of a fire detection and alarm system—encompassing control panels, manual call points (MCPs), and notification appliances—is presented to demonstrate the financial feasibility and critical necessity of such safety investments. A significant portion of the research explicitly addresses the problem domain of false alarms. The study systematically identifies primary causes, such as environmental factors, inappropriate sensor placement, equipment faults, and human error, and proposes targeted mitigation strategies. These strategies include the implementation of sensitivity-floating detection systems, multi-stage alarms, application of pattern recognition methods, and adherence to stringent, routine maintenance protocols. The findings establish that the integration of strategically positioned, application-specific detection systems profoundly enhances the safety integrity of LPG plants. By strictly adhering to national and international safety standards (such as NFPA 72, IS-2189, and OISD guidelines) and adopting advanced false-alarm correction methodologies, industrial facilities can achieve a highly reliable, early-warning fire protection mechanism that guarantees swift emergency response and continuous systemic risk reduction