TCCQS Ev.3 Global Audit Program

TCCQS Ev.3 Global Audit Program

Fire Control & Combustible Materials Module

This module serves as a guide to the auditor in completing the compliance part of the audit of an operation. The auditor will determine whether or not the Operation is complying with the specifications and requirements of The Coca-Cola Company by completing this audit module.

Plant: Date:

Auditor(s):

------

Yes / No

Are the current local regulations maintained and followed?
Has the site conducted and documented a risk assessment to identify all potential fire hazards and to review controls in the workplace ?
Has the site established a written Emergency Response and Evacuation Plan that includes fire?
Has the staff been trained properly regarding fire hazards and controls ?
Has the site got all the necessary fire signage, alarms, emergency exits and lighting ?
Has the facility established a clear smoking policy?
Does the plant have the necessary fire fighting equipment?
Does the facility have an inspection and maintenance program in place for the fire protection systems?
Does the site ensure a safe interior and exterior storage of goods ?
Do the site and storage area constructions follow the requirements regarding fire control?
Does the facility have an appropriate water supply for fire protection purposes?
Does the building construction comply with the Company’s requirements?
Do the facility’s fire alarm systems comply with Company requirements?
Does the facility has an automatic fire control system
Has the site developed a written fire impairment procedure?

2) Reference Standards List:

Fire Control Requirements
Combustible Materials Requirements

3) Specifications and Requirements Summary:

Specifications / Requirements
1 /

Are the current local regulations maintained and followed?

Current copies of applicable local regulations available
Facility has implemented management practices and controls in accordance with these regulations or Company requirements whichever are the most stringent

2 /

Has the site conducted and documented a risk assessment to identify all potential fire hazards and to review controls in the workplace?

Risk assessments conducted for insurance placement provided e.g. by Global Risk Consultants, Factory Mutual, Alliance etc. fulfill this requirement /

The site has identified all potential fire hazards and controls in the workplace
Risk assessment reviewed annually or whenever facilities , equipment or processes are added or modified which can create or change potential fire hazards or whenever there has been a fire incident

3 /

Has the site established a written Emergency Response and Evacuation Plan that includes fire?

Based on the (fire) safety assessment and local regulations the site has established a written Emergency Response and Evacuation Plan which describes the prevention controls and the response procedures in the event of a fire

The Fire Emergency Plan section contains the following elements:

Response actions for probable and “worst-case” fire scenarios
Personnel roles and responsibilities for incident control
Communication & coordination with outside responders and agencies
Availability and use of control equipment and PPE
Isolation of electrical and/or hazardous materials (e.g natural gas, LPG, acids, caustic) supplies in the involved area
Ensuring fire control equipment ( pumps, sprinkler control valves etc. ) are in operating condition
Coordination with other site emergency actions including site evacuation, spill response, medical treatment and incident management
Reporting and communication with local authorities and Company management through linkage with the IMCR plans
Defining salvage, restoration, decontamination and waste disposal actions and responsibilities
Accident investigation and corrective action process. All fire incidents must be formally investigated to identify the root cause and corrective actions implemented
Training requirements and responsibilities
4 /

Is there an evacuation plan developed?

/ Evacuation plan includes:

Sounding alarms
Assembly points
Roles and responsibilities
Head count verification
Accounting and management of visitors
All clear

Maps showing the closest exit locations posted in each area of the facility
5 /

Has the staff been trained properly regarding fire hazards and controls?

/ General training requirements

Documented initial training on the Emergency Plan and Evacuation Plan
General fire prevention
The method of raising an alarm, the location of alarm call points and alarm indicator panels
The action to be taken upon hearing an alarm
Correct method of calling the fire brigade
Location and practical use of firefighting equipment
The evacuation procedure for the building, escape routes, assembly points and roll call procedures
Stopping machines and processes and isolating power supplies where appropriate
Training is refreshed annually

Fire drills

Annual fire drills conducted to test effectiveness of the Fire Emergency Plan
If plant operates in more than one shift, drills conducted in each shift
Each drill is monitored, recorded and the overall performance is measured
Appropriate corrective actions taken

Fire control equipment

Employees who are expected to use fire extinguishers receive initial training and annual refresher training on the use of fire extinguishers
Training on fire extinguishers includes a “hands-on” training on real fire
Employees who are expected to use hose reel systems receive initial and annual refresher training on their use
Training on hose reels includes “hands-on” training on real fire

6 /

Has the site got all the necessary fire signage, alarms, emergency exits and lighting?

/ Signage

Printed notices highlighting the action to be taken by staff in case of fire are posted in all parts of the premises
The notices include simple site map, showing the exact position of the fire control and fighting equipment, exits and nearest escape route
Fire equipment and fire exits prominently and clearly signed or posted
Signs are elevated in areas where they may become obstructed
Signs written in local language pictograms are used
Illuminated signs and acoustic signal alarms provided with emergency power supply

Fire exits and emergency lighting

An adequate number of fire exits are available in the workplace. The number depends on the number of employees, lay-out of the workplace etc.
Each exit discharge leading directly outside or to a street, walkway, refuge area, public way or open space with access to the outside
The exit doors swing out in the direction of exit travel
Exit door can be opened by all employees at all times without keys, tools or special knowledge, they must never be locked
Secured doors fitted with “panic bars” and turnstiles fitted with emergency releases or bypass doors to allow unrestricted egress
Unobstructed access to emergency exits is maintained at all times and controls to ensure that access is kept clean
Emergency lighting provided throughout the facility
All emergency exits have illuminated signs, to indicate “EXIT” in local language
Stairs for all elevated building exits, ladders NOT acceptable

Alarms

Facility has installed fire alarms according to the local regulations and fire risk assessment
Fire alarms must sound an audible alarm throughout the facility, with visual alarms in high noise areas
Smoke and/or heat detection systems in all areas except where sprinkler protection is provided or where local operating conditions negate the installation ( eg near bottle washing stations )
Pull stations or similar alarms at exterior exits or near significant hazards ( e.g. flammable liquid storage, boiler room etc. ) that transmit as a minimum an audible or visible alarm, or trigger an immediate visual observation by Security or other personnel

7 /

Has the facility established a clear smoking policy?

A clear smoking policy established and communicated to all personnel, visitors and contractors
Smoking prohibited in all interior areas except in designated smoking areas or private offices if permitted by local management
Signs identifying clearly “Smoking” and “No Smoking” areas
Equip smoking areas with sand-filled or similar non-combustible ashtrays
Designated “ No Smoking Areas “ at least 8 m beyond any storage of flammable liquids or gases and 5 m from combustible material storage

8 /

Does the plant have the necessary firefighting equipment?

/ Hose Reel Systems

Hose reel systems provided as required by local regulations

Protect the equipment located outside or in environments that can damage the equipment

Fire Extinguishers

Fire extinguishers to be located according to local requirements and possible hazards
Extinguishers with the right class to be used for different purposes ( Class B for flammable liquids, class C for electrical equipment ) or multi-rated extinguishers
Elevated signs posted to indicate the locations
Protective covers used on equipment located outdoors or where it can be damaged
Maintain clear access to the fire extinguishers
If fire extinguisher is used or discharged, it must be removed and replaced by another while being recharged

9 /

Does the facility have an inspection and maintenance program in place for the fire protection systems?

For more details on inspection and maintenance see “Company’s Fire Protection Equipment Maintenance Guidelines” /

All fire protection systems are inspected and maintained in accordance with local requirements and manufacturer’s instructions
The results are recorded on a label or tag fixed to the equipment ( if possible ) and the records are maintained

10 /

Does the site ensure a safe interior and exterior storage of goods?

/ Interior storage

All areas are kept clean from flammable and combustible materials (loose cardboard, empty containers, unused pallets etc.)
A cleaning program in place to remove debris to safe outside location each shift
Do not permit accumulation of dust and initiate cleaning activity if a visible accumulation is noted.
All hose reels, fire extinguishers and fire exits easy accessible and kept clear of obstructing storage
Combustible materials segregated from flammable materials, ignition sources and fire accelerants ( like oxidizing materials )
Combustible or flammable materials not stored in or under stair wells, in pedestrian aisles or other fire escape locations
Flammable maintenance and/or cleaning materials, except the amount needed in day to day operations, stored in special safety cabinets or equivalent, and in locations segregated from process or bulk storage areas.
Store pallets and combustible packaging materials in areas and in quantities to minimize fire risk. Single pallet stacks in unprotected areas, or the use of sprinkler protection for these areas are recommended
Storage meets local requirements regarding spacing and stacking

Exterior storage

Outside storage must not obstruct hydrants, sprinkler control valves or other firefighting equipment
Combustible materials not stored within 1m (3 ft) from building structures
Combustible materials not stored under air intakes, eves or roof overhangs that can direct smoke or fire into the building
Maintain a 7.5 m (25 feet)radius free of fire hazards around outside storage areas of combustible and flammable materials

The following requirements are only applicable to Coca-Cola Company operations ( CBO’s )
11 /

Do the site and storage area constructions follow the requirements regarding fire control?

Panel wall constructions is typically used in operations to provide rated firewalls with surfaces that are amenable to food manufacturing cleaning and GMP requirements. Panels are typically contracted by “sandwiching” insulation between surfacing material such as metal sheeting or concrete. The insulation used, thickness of insulation used, and the surface construction will determine the fire rating of the panels
Environmental and fire safety regulations may dictate how drainage of firefighting water should be handled /

Buildings are constructed and provided with fire control according to the local safety regulations as a minimum
To the greatest extent possible, non-combustible materials are used

Panel Walls

Panel walls rated by an accredited or government –approved agency and approved by local authorities for the intended use
Non-combustible insulation, such as mineral wool or fiberglass are used in all construction, including panel walls. Other insulation materials may be used in panel wall constructions if approved by an appropriate listing agency or government authority
Polyurethane ,polyisocyanate or polystyrene insulation only used as insulation material if an automatic sprinkler protection system is provided and under certain conditions ( for details see Fire Control requirements )

Roof constructions

Built-up insulation assemblies on steel deck roofs must be listed as Factory Mutual approved Class 1 or equivalent.
All other insulating materials listed as non-combustible by an approval agency

Ventilation

Emergency smoke and heat venting provided in combustible storage areas
Mechanical ventilation provided for flammable liquid storage areas to maintain vapors to below 25%LEL
Emergency venting on flammable liquids storage tanks

Drainage

Drainage arrangements in place to direct spills of flammable liquids and firefighting water to a safe location for clean up

Electrical systems

Only dry-type transformers are used inside buildings
Oil-filled transformers located outside the building at min distance of 15m (60 ft) or facing 2-hour rated wall, on a curbed concrete containment slab
If oil filled transformers are located inside, they are treated as combustible materials and provided with the required fire controls
No PCB oil transformers are used
Cabinets with vital PLC’s, computers or electrical equipment have smoke detectors directly in the cabinet

12 /

Does the facility have an appropriate water supply for fire protection purposes?

The type of fire protection system that is used by the facility will determine the acceptable water supply specifications.
The supply can be either a public water supply or an internal system
Public water supply is considered adequate if :
Provides minimum flow of 3800L/min , at a rated pressure not to exceed 10 Bar
No single impairment eliminates full service
The full fire flow is available after 3 days drawdown at the maximum system demand, with the single largest pumping station or supply out of service /

The water supply system meets the specifications regarding flow and pressure set by local regulations
Dedicated fire pump to attain the desired flow and pressure
Appropriate pumper connections provided to the water systems feeding inside hose connections to permit fire equipment to hookup to the system
Control program is established to assure that fire control system piping is protected against freezing and exterior surface corrosion
Color code is used to identify the systems ( mostly red )
If sprinkler system is in place the water supply is designed to accommodate the required sprinkler demands
All necessary alarm systems are provided for the fire water supply
A yard main ( preferably used as ring main ) installed ( minimum diameter 150mm )
Pumper connections situated in locations that permit firefighters to directly pump water into the yard main system
Maintenance program for the water supply systems in place

13 /

Does the building construction comply with the Company’s requirements?

Deluge sprinklers at conveyors openings is an acceptable alternative to shutters / Fire Separations

2-hour rated fire separation used for the following area’s:

Flammable liquid and gas storage, use, production and filling areas ( see flammable liquids requirements )
Designated hot work areas ( see hot work requirements )
Areas containing ammonia compressors, condensers, exchangers, receivers and other gas hold-ups
PET bottle manufacturing and storage areas for resin, preforms and finished bottles
Non-electric boilers, generators, fire pumps or other fuel-fired apparatus
Combustible materials storage ( e.g. packaging, crates , pallets )

A 1-hour rated separation is sufficient for computer and PLC rooms, motor control centers and telephone switch gear rooms and for interior storage areas for combustible materials in conjunction with automatic fire controls ( sprinklers )
Plants with property values > $50,000,000 or if warehouse stock is very valuable or cannot be replaced without interruption in sales and potential loss in market share, a minimum 3-hour rated free standing fire wall ( or two 2-hour walls tied to separate building frames ) is provided between production and warehousing areas
Any openings in the fire-rated separations must be fitted with automatic fire-rated doors, shutters and conveyor closures of similar rating
All pipes, conduit and other penetrations sealed equal to the wall rating
Ductwork penetrating a fire barrier has internal dampers
No plastic insulation on piping or other utilities used in fire-risk areas

Fire Doors

Fire-rated separations have automatic fire doors of similar rating
Frames and mounting hardware installed so that fire rating is maintained
All fire doors and frames labeled with their rating from installation
Records of original installation are retained
Fire doors installed on the side of the wall outside the hazard
All fire doors equipped for automatic operation. Fire doors or shutters have operating devices
Vision panels only installed in doors of ratings of 2-hours or less

Conveyor Openings

Conveyor openings in rated fire walls closed off with fire shutters equivalent to the wall rating
Ensure that fire door can close completely over the protected opening
Procedures established to ensure that conveyors shutters are unobstructed when the line is not operating

Fire exits

Construction materials used to separate an exit from other parts of the building have a 1-hour fire rating if exit connects 3 or fewer stories, and a 2-hour rating if the exit connect 4 or more stories
Opening into a fire exit is protected by a self-closing door that remains closed or closes automatically upon fire alarm.

14 /

Do the facility’s fire alarm systems comply with Company requirements?