2. Abhijit Haldankar
BE Chemical Engg.
(UDCT,Mumbai)
25+ yrs exp.
Now…
Process & Safety Consultant
2010-2016
Linde Engineering Pvt Ltd
2002-2010
Reliance Industries Ltd
1995-2002
Indian Petrochemicals Corporation
Ltd
Consultation for
• Process Safety activities
• PSV Design
• SMPV Competent Person
• Pressure Surge Analysis
• Explosion Protection
• Fire Protection
• F&G Detection
• Environment Protection
• HAZOP / HAZID / SIL study
INTRODUCTION
3. INTRODUCTION
Name : Abhijit Haldankar
BE (Chem) – UDCT (Mumbai)
Total 25 Years of experience
With Linde Engineering India
between 2010 to 2015
Process & Environmental Safety
Worked in gas based Ethylene plant
for 15 yrs between 1995 to 2010
4. SAFETY CONTACT
Fire Incident
Company : FRP Coating Comapny
Flammable Material : Resins (Used as raw material for
FRP Products)
Incident : Fire occurred in “Sheet Metal FRP Coating
Machine” where FRP material is being heated and
applied on sheets.
It spread in nearby area where resin & paint was stored
One day before small fire was occurred in same machine
which was extinguished by worker using DCP.
Waste area was also engulfed
6. AGENDA
Fire Basics
Fire Protection Regulations & Standards
Fire Protection System
Basis for Fire Protection System Design
Fire Water Demand
Fire Water Pump & Storage
Fire Water Network
Fire Fighting Equipments
Spray System Design
Foam System
9. What is fire ?
Combustion of flammable or combustible material
Type of fires
Not A, B,C … We all know these fire types.
For process plants we should know more than this.
FIRE - BASICS
10. Types of Fire
Flash Fire
Pool Fire
Jet Fire
Fire Ball
Solid Fires
FIRE- BASICS
11. Flash Fire
Vapour cloud
Flame Front speed
Time duration – Very short
Generally Flash fire ended in sustained pool fire or jet
fire
Consequence of flash fire is burn injury. It is normally
estimated for “how much area” is covered by vapour
cloud.
FIRE - BASICS
12. Pool Fire
Liquid spill or leak
Major consequence is heat radiation
It is characterized by flame length &
Pool size
Significance for Fire Protection Design
Cooling requirements (for tanks, process
areas etc)
Fire Hazardous Area
Requirement of Passive Fire Protection
FIRE - BASICS
13. Jet Fire
Pressurized gas leak
Major Consequence heat radiation
Jet/Flame Length
Characterized by discharge rate
and flame length
Significance for fire protection
Cooling requirements (Bullets /
Sphere)
FIRE - BASICS
16. Understand the flammable materials involved
Locate the inventory of flammable material
Available fire fighting support from outside
Applicable Standards and Codes
Areas to be protected
Process Plant – Open Area
Process Plant – On Structures
Process Plant – Inside Building
Process Buildings In plant Area
Non Process Buildings in plant area
FIRE PROTECTION FUNDAMENTALS
17. Active Fire Protection
Water Based Fire Protection
Fire Water Network
Hydrants
Monitors
Hose Reels
Spray Systems
Gas Based Fire Protection
Clean Agent System
CO2 flooding system
FIRE PROTECTION FUNDAMENTALS
18. Passive Fire Protection
Spacing & Layout
Fireproofing
Containment & Drainage
Fire Walls
Hazardous Area Classification
FIRE PROTECTION FUNDAMENTALS
20. For Process Plant Area
Indian Standard
TAC
NFPA
OISD
API
For Buildings
National Building Code
International Building Code
International Fire Code
FIRE PROTECTION REGULATIONS &
STANDARDS
22. Major Indian Standards
TAC : Tariff Advisory Committee Guidelines
IS 13039 : External Hydrant System
IS 12469 : Fire Water Pumps (Pump & Storage Capacity)
IS 15325 : MV & HV Spray System
OISD 116 : Fire Protection for Refinery & Petrochemicals
Plant
OISD 117 : Fire Protection for Petroleum Depots
OISD 189 : Fire Protection For Oil & Gas Installations
OISD 244 : Standard for Petroleum Depots
Requirements
FIRE PROTECTION REGULATIONS &
STANDARDS
23. Major International Standards
NFPA 10 : Portable Fire Extinguishers
NFPA 13 : Sprinkler System
NFPA 14 : Fire Water Network (Hose System)
NFPA 15 : Spray System
NFPA 20 : Fire Water Pumps
NFPA 24 : Private Fire Water System
NFPA 30 : Flammable & Combustible Liquid Codes
NFPA2001 : Clean Agent Fire Extinguishing System
API2001 : Fire Protection in Refineries
API2218 : Fireproofing Practices in Refineries
FIRE PROTECTION REGULATIONS &
STANDARDS
25. Remember the “Fire Protection Fundamentals”?
Understand the “Layout”
Understand the flammable materials handled and their
location , inventory in plant
Fix the applicable codes
Now start “Fire Protection System Design”
FIRE PROTECTION SYSTEM DESIGN
26. What do you understand by “Fire Protection System
Design”?
Design Basis of the Proposed System
Water Demand Calculations
Fire Water Network Drawing
Fire Water Network Hydraulics
Fire Water System P&IDs
Fire Water Pump & Storage Datasheets
Fire Protection Equipment Datasheets
Spray System Design
FIRE PROTECTION SYSTEM DESIGN
27. What do you understand by “Fire Protection System
Design”?
Specification of gas based fire protection system (Clean
Agent System)
BOQ for Fire Protection System
FIRE PROTECTION SYSTEM DESIGN
28. Fire Protection System Design Basis
Objective of Fire Water System
Chemicals handled in the plant
Location & Inventory of Flammable Material in plant
Type of Protection envisaged
Fire Water Demand
Fire Water Pump & Storage
Fire Water Network
Fire Water Distribution
• Monitors
• Hydrants
• Hose Reels
• Spray System
FIRE PROTECTION SYSTEM DESIGN
29. Fire Protection System Design Basis
Objective of fire protection system is mainly to control fire
till external help arrives.
Type of Protection envisaged
Process area Coverage for all hazard area
Area shall be accessed from at least two sides
Otherwise spray system can be proposed
Utility & other non plant areas also needs to be covered
but the number of hydrants required will be less
Storage Area
Tanks can be accessed from all four sides by monitors
Code & Standard requirement for spray system
FIRE PROTECTION SYSTEM DESIGN
30. Fire Protection System Design Basis
Fire Water Demand Basis shall be specified
Based on Number of Hydrant Points
Based on number of simultaneous fires (Single / Double )
Based on Spray System
FIRE PROTECTION SYSTEM DESIGN
32. Single Fire Scenario / Double Fire Scenario
Demand based on number of hydrants points
Demand for Spray System
FIRE WATER DEMAND CALCULATION
33. Demand Based on numbers of Hydrant points
As per TAC & Indian Standard,
Determine Hazard Category of Industry
Light Hazard
Ordinary Hazard
High Hazard (A)
High Hazard (B)
Determine number of hydrant points required on proposed fire
water network.
Based on number of hydrants & Hazard Category we can
decide FW pump required capacity and storage capacity
FIRE WATER DEMAND CALCULATION
34. Pump Capacity as per TAC & IS (12469)
FIRE WATER DEMAND CALCULATION
35. FIRE WATER DEMAND CALCULATION
Pump Capacity as per TAC & IS (12469)
36. FIRE WATER DEMAND CALCULATION
FW Storage Capacity as per TAC & IS (12469)
38. FIRE WATER DEMAND CALCULATION
Demand based Spray System Water Requirements
When to provide Spray System?
For class A Petroleum Product storage tanks
For Class B Petroleum Product
Floating roof storage tanks with diameter > 30m
Fixed roof storage tanks with diameter > 20m
LPG / Hydrogen / Flammable Liquefied Gases storage ,
Pumping and Gantry
Process Areas
Inaccessible Flammable handling areas
Vessels handling Class A/B > 50m3
AFCs above Hydrocarbon piperacks
Columns with Height > 45m
39. FIRE WATER DEMAND CALCULATION
Calculate Spray System Water Requirements
Application Rates (Refer the applicable standard followed
for design)
Tanks : (OISD 116/117/244)
3 LPM/m2 (For tank on fire & tanks within R+30m)
1 LPM/m2 ( For tanks beyond R+30m)
Pumps & Loading Gantry : 10LPM/m2
Process Area : 10.2 LPM/m2
40. FIRE WATER DEMAND CALCULATION
Calculate Spray System Water Requirements
Based on application rate and protected area calculate
the water requirement for spray
Add supplementary water supply to this flow to arrive
water requirement for the protected area.
41. FIRE WATER DEMAND CALCULATION
Final Water Demand
As per philosophy single or double fire, fire water
demand can be arrived.
It is highest of the water demand based on hydrants and
spray system requirement
It is highest in case of single fire scenario
It is addition of top highest water requirements +
supplementary water , in case of double fire scenario
43. FIRE WATER PUMPS
The calculated water demand can be provided by one or
more working main fire water pumps.
Pumps can be electric motor driven or diesel engine
driven
Number of diesel driven pumps shall be minimum 50% of
the total number of pumps (inclusive of standby pumps)
The standby pump requirement depends on type of
installation/facility.
Applicable Standard : NFPA20 & IS12469
44. FIRE WATER PUMPS
The diesel engine driven pump shall be provided with
diesel day tank dedicated for each pump. Day tank
should be for maximum 6 hr running of pump.
The pumps shall be capable of discharging 150% of its
rated discharge at a minimum of 65% of the rated head.
The Shut-off head shall not exceed 120% of rated head
The jockey pump capacity shall be between 5 to 10% of
main FW pump.
Jockey pump is electrical motor driven pump.
45. FIRE WATER PUMPS
Types
Horizontal split case pump
Vertical split case pump
Vertical in-line pump
Vertical turbine pump
47. Pump
Casing Vent (Air release valve)
Casing Drain
Leak from sealing gland (Arrangement to be provided for drain)
Discharge Common Header
Pressure Gauge
Pressure Switches / Transmitters
Common Isolation Valve
FIRE WATER PUMPS - FITTINGS
48. Electrical Motor
Jockey pump
Main Fire water pump
Diesel Engine
Main Fire Water Pump
Electrical Motor Powered directly from DG Set
Main Fire Water Pump
Fire Water Pumps Data Sheet & Specification
FIRE WATER PUMPS - DRIVERS
49. FIRE WATER PUMPS
FW Pump start up sequence
Jockey pump will keep FW header pressurise
It will start when header pressure reach certain low value and stop
when certain high value is reached.
In case of fire, actuation of any spray system or opening of any
hydrants / monitors will decrease header pressure due to increase
in FW flow.
At low FW header pressure first FW main pump will start.
If header pressure further drops second pump will start.
The stop of FW pump will be manual.
50. FIRE WATER PUMPS
FW Pump panel
Electrical mains supply is received in panel
Low pressure signal (normally digital signal) to panel
Logic to start / stop jockey pump is executed in panel
The logic to start main pumps is executed in panel
Signal for diesel pump will go from panel to diesel engine panel
Panel have pumps status lamps, hooter , current indication
53. FIRE WATER STORAGE
As per Hazard Category Fire water storage capacity can
be decided based on Fire Water Demand/Pump capacity
For refinery or petrochemical complex it is 4hr running of
main FW working pump.
FW Storage can be above ground or underground
FW Storage can be ,
Steel Tank
RCC Tank
Ponds
Reservoir
54. FIRE WATER STORAGE
FW Storage shall have two compartments of equal
capacity
Pump suction shall be from both compartments
Make-up water line is required. Reliable make-up can
used to reduce storage size.
Level measurement is required
If fire water is stored in underground tanks, an overhead
water tank of sufficient capacity shall be provided for
flooded suction
56. FIRE WATER NETWORK
Fire Water Network consists of following,
Fire Water Mains , Sub Headers and Risers
Hydrants
Monitors
Hose Reels
Spray System
Foam System
58. FIRE WATER MAINS
The fire hydrant mains should always be laid in rings or
cross-linked rings (IS13039/5.4)
The minimum size of FW mains shall be 6” (IS13039/5.4)
Adequate number of sluice valves should be installed
according to the general layout of the installation.
Generally after 300m isolation valve should be provided.
59. FIRE WATER MAINS
Hydrants and monitors to be placed on network to cover
entire facility.
Maximum distance between two hydrants is specified in
standards. It is 30m in process area and 45m in utility
area.
In other areas it can be 60m.
In petrochemical plant or refinery it is not exceeded
beyond 45m.
The congested areas which can not be covered with
hydrants and monitors can be covered through fire water
spray.
The congested area can also be covered using hose
reels depending on the criticality and inventory.
60. FIRE WATER MAINS
Storage tanks shall be covered from opposite sides by
preferably monitors
If we ensure the coverage from opposite side and access
around the storage area, then we need not provide spray
system.
For smaller tanks , which can be covered through
monitors , this can be applied.
For bigger storages, spray needs to be provided. (It may
also required by regulation & standard)
61. FIRE WATER MAINS
On Plant Structures, risers to be provided along the
staircase.
Hydrant (Landing valve) and Hose Reel to be provided at
each floor
Based on floor area additional risers to be provided to
ensure coverage of all floor area.
62. FIRE WATER HYDRANTS
Hydrant can be single headed or
double headed
In refinery installation double
headed hydrants shall be used
Hydrant can be installed on stand
post or on down comer
Applicable Standard
IS 13039
NFPA 14
Water Flow : 36m3/hr
63. FIRE WATER HYDRANTS
Spacing between two hydrants
shall be not more than 30m in
process area and 45m -60m in
utility & non plant area.
Hydrant shall be located
maximum 15m from the
protected equipment/Building
Hose box is required near each
or alternate hydrant point
65. FIRE WATER MONITORS
Water Monitors are used to cool the equipment from
distance with higher flow rates.
It is fixed installation.
It’s direction and angle to horizontal can be adjusted.
Monitor can be water-cum-foam monitor
73. FIRE WATER SPRAY SYSTEM
Spray System can be,
Medium Velocity Spray System
High Velocity Spray System
Actuation of Spray System can be,
Automatic
Manual
74. FIRE WATER SPRAY SYSTEM
Components of Spray System
Deluge Valve (For Automatic Actuation) / Manual Valve
Isolation valves
Bypass valve (In case of Deluge valve)
Strainer
Spray Rings and Spray Nozzles
Sensing line rings and QB sensors (For Automatic
Actuation). It can be of water or instrument air.
Actuation can be based on other fire detectors also like
flame detector or heat detectors
75. FIRE WATER SPRAY SYSTEM
Spray System Components : Deluge Valve Assembly
77. FIRE WATER SPRAY SYSTEM
Automatic Actuation of Spray System
Principle of actuation : The deluge valve is a diaphragm
valve. It remains in close position by means of pressure on
diaphragm by fluid in sensing line (water or IA)
Due to heat (60 to 75 degC) QB sensor on sensing line will burst
and depressurize the line. This will actuate PALL/PSLL and
eventually deluge valve.
The depressurization of sensing line continues and deluge can
be open by actual depressurization of pressure on diaphragm.
The pressure on diaphragm can be released manually through
drain valve, to open deluge valve manually in field.
78. FIRE WATER SPRAY SYSTEM
Sensing Line
Supply
Sensing Line
To Equipment
80. FIRE WATER SPRAY SYSTEM
Spray System Design
Spray System is hydraulically sized to provide calculated
water flow for protected surface
Based on dimensions of protected surface decide no of
rings.
The pressure requirements at spray nozzles are between
1.5 to 3.5 kg/cm2g
Q = flow rate of the nozzle, lpm
K = K-factor
P = pressure at nozzle, bar(g)
81. FIRE WATER SPRAY SYSTEM
Spray System Design
Selecting spray angle , based on converge of one nozzle,
number of nozzles in each ring can be estimated.
From no. of nozzles we get flow through each nozzle.
88. FOAM SYSTEM
Fixed Foam System
Foam Pump
Bladder Tank
Proportionator
Piping
Material of construction
Actuation
Automatic (Through Detection System)
Manual
90. FOAM SYSTEM
Semi Fixed Foam System
Semi Fixed System is an installation where the hazard is
equipped with fixed discharge device(s), which connect to
piping that terminates a safe distance from the hazard,
normally outside the dike wall.
Foam producing materials are transported to the scene
after the fire starts and are connected to the piping.
92. FOAM SYSTEM
Water cum Foam Monitor
Fixed foam monitors are used to fight fire from a
predetermined safe distance, while portable applicators
and nozzles cover shadow areas not reachable by the
monitors.
Shall be used as the material handled in process area,
storage area is highly flammable liquids which will cause
pool fire
Volume -100 lit of foam solution
Water cum foam monitor shall be as per IS:8442
These monitors are adjustable and can be used in two
modes: jet or fog.
97. PASSIVE FIRE PROTECTION
Fire Proofing
Layout and Safe Distance
Dykes and Drain
Prevention of Ignition (Area Classification)
98. PASSIVE FIRE PROTECTION
Fire Proofing
Applicable Standard
OISD164
API2218
Fire Potential Equipment
Any Equipment Handling Liquid Hydrocarbon or Liquefied Gas
Fire Hazardous Area
General Requirement of fireproofing
Duration
Temperature
101. BUILDING FIRE PROTECTION
Whether it is Building or Structure?
What is Structure?
Process Structure is Industrial occupancy designed for, and suitable
only for , a particular type of processing operation
It is characterized by relatively low density of employee population
102. BUILDING FIRE PROTECTION
Structure can be,
Open Process Structure
No interior or exterior walls
Better air circulation
More access for effective fire fighting
Enclosed Process Structure
May have complete or partial walls
and roofs
Poor air circulation increases chances
of formation of flammable mixture and
hence fire
Limited access for fire fighting
Entry for only trained fire fighters
FW run off can not be accommodate
readily
103. BUILDING FIRE PROTECTION
Check for Applicable Standards and Regulations
National Building Code
International Building Code
Factory Rule
Fire Rule
Country / State Specific Regulations
104. BUILDING FIRE PROTECTION
What is occupancy category of the building?
As per NBC,
Residential Building (A)
Educational Building (B)
Institutional Building (C)
Assembly Building (D)
Business Building (E)
Mercantile Building (F)
Industrial Building (G)
Storage Building (H)
Hazardous Building (J)
106. BUILDING FIRE PROTECTION
Note to Table in NBC
The requirements given in this table for Group G
Industrial Buildings are for small scale industry units. For
industries the requirements will have to be worked out
on the basis of relevant Indian Standards and also in
consultation with local fire authorities.
107. BUILDING FIRE PROTECTION
Fire Protection For Buildings
Riser or Down comers with Hydrants
Yard Hydrants
Hose Reels
Fire Extinguishers
Automatic Sprinkler
Smoke Detectors
Heat Detectors
108. BUILDING FIRE PROTECTION
Sprinkler Requirement in Buildings
In enclosed building access for fire fighting during
emergency is limited
Fixed fire fighting system is preferable
Local Regulation may require sprinklers based on hazard
category of flammable material handled
IBC and NFPA30, NFPA13 provide guideline for the sprinkler
requirement
Sprinklers can be Wet or Dry Type.
109. DRY SPRINKLER
Dry Sprinkler
The maximum area of
coverage of any sprinkler
shall not exceed 400 ft2
(36 m2).
Maximum distance
between sprinkler
Minimum distance
between sprinkler
111. WET SPRINKLER
Wet Sprinkler – Pendent
Upright Sprinkler
The maximum area of
coverage of any sprinkler
shall not exceed 225 ft2
(21 m2).
Maximum distance
between sprinkler
Minimum distance
between sprinkler
113. HOSE REEL
Hose reel stations shall be provided in the Reaction Area,
Distillation Area and Utility area structures
Each floor of the structure will have hose reel connected to
riser
Capacity – 15 m3/hr, Length – 30 m of 1½ “non-collapsible
hose with adjustable fog/jet nozzle mounted on a
horizontal drum and cradle.
114. FIRE EXTINGUISHER
Fire Extinguishers are first aid fire fighting equipments.
They can be portable or wheel mounted
Used to put out fire by directing action on a substance
that catches fire on burning
Cooling of the exposed substance to fire by forming coating
over the flame
Deprived of oxygen by cutting off O2 supply
Fire extinguishers are placed in plant area at strategic
locations for first aid firefighting of small fires
117. FIRE EXTINGUISHER
DCP Fire Extinguisher is most commonly used.
Its main components are,
Cylindrical vessel/tank
Discharge Hose
Propellant
Extinguishing Agent
Release lever
Handle
Valve assembly
Fire extinguishers shall be as per IS: 15683
118. FIRE DETECTORS & ALARM
Fire Detectors
Fire detectors are provided to detect fire at early stage.
Depending on the material involved and type of fire
these sensors / detectors can be provided.
Type of fires,
Pool Fire or Jet fire : Rise in temperature of surrounding
Pool fire involving heavier hydrocarbon : Flame is detected
Electrical fire or fire involving combustible material : Smoke is
detected
119. FIRE DETECTORS & ALARM
Type of Fire Detectors
QB Sensors
Heat Detectors
Point Detector
Linear Detector
Flame Detectors
Smoke Detectors
120. FIRE DETECTORS & ALARM
Fire Alarm System
In case of any emergency, person who has detected the
fire or emergency can communicate to concern agencies
through fire alarm system
Fire Alarm System consists of ,
Manual Call Point
Cables
Addressable or Non-addressable control panel
MCPs should be installed.
Along the escape route
Along the road
At exit of each building or enclosure
121. RECAP…….
Fire Basics & Objective of Fire
Fire Protection Regulations & Standards
Fire Protection System Design
Fire Water Network
Fire Water Demand
Fire Water Pump & Storage
Fire Fighting Equipments
Spray System
Foam System
Building Fire Protection
Fire Extinguishers
Fire Detection & Alarm System