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Fire Protection Training_QPS_26DEC20_Final.pptx

This document provides an overview of a fire protection training session at QPS in Vadodara, India. It introduces the trainer, Abhijit Haldankar, who has over 25 years of experience in process and environmental safety. The agenda covers fire basics, regulations and standards, fire protection system design, fire water demand calculations, fire water pumps, and other fire protection topics. A recent fire incident at an FRP coating company is also described, where a fire started in a sheet metal coating machine and spread to a nearby resin storage area.

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FIRE PROTECTION TRAINING AT QPS, VADODARA By Abhijit Haldankar 26.10.2020
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
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
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
SAFETY CONTACT  Fire Incident  Videos 2, 3
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
AGENDA  Building Fire Protection  Fire Extinguishers  Fire Detection & Alarm System
FIRE BASICS
 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
 Types of Fire  Flash Fire  Pool Fire  Jet Fire  Fire Ball  Solid Fires FIRE- BASICS
 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
 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
 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
 Fire Triangle  Fuel  Heat / Ignition  Oxygen FIRE- BASICS
FIRE PROTECTION FUNDAMENTALS
 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
 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
 Passive Fire Protection  Spacing & Layout  Fireproofing  Containment & Drainage  Fire Walls  Hazardous Area Classification FIRE PROTECTION FUNDAMENTALS
FIRE PROTECTION REGULATIONS & STANDARDS
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
Regulations  Factory Act  Factory Rule (e.g. Gujarat Factory Rule)  Fire Rule (e.g. Maharashtra Fire Rule)  Petroleum Rule  SMPV Rule  Oil Mining Regulation (OMR) FIRE PROTECTION REGULATIONS & STANDARDS
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
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
FIRE PROTECTION SYSTEM DESIGN
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
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
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
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
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
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
FIRE DEMAND CALCULATIONS
 Single Fire Scenario / Double Fire Scenario  Demand based on number of hydrants points  Demand for Spray System FIRE WATER DEMAND CALCULATION
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
 Pump Capacity as per TAC & IS (12469) FIRE WATER DEMAND CALCULATION
FIRE WATER DEMAND CALCULATION  Pump Capacity as per TAC & IS (12469)
FIRE WATER DEMAND CALCULATION  FW Storage Capacity as per TAC & IS (12469)
FIRE WATER DEMAND CALCULATION  Example
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
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
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.
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
FIRE WATER PUMPS
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
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.
FIRE WATER PUMPS Types  Horizontal split case pump  Vertical split case pump  Vertical in-line pump  Vertical turbine pump
 Suction Strainer Isolation Valve (Other than butterfly Valve) Foot Valve (For negative suction) Priming Arrangement (For Negative suction) Pressure Gauge  Discharge Pressure Gauge Isolation Valve NRV FIRE WATER PUMPS - FITTINGS
 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
 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
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.
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
FIRE WATER PUMPS  FW Pump panel
FIRE WATER STORAGE
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
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
FIRE WATER NETWORK
FIRE WATER NETWORK Fire Water Network consists of following,  Fire Water Mains , Sub Headers and Risers  Hydrants  Monitors  Hose Reels  Spray System  Foam System
FIRE WATER NETWORK
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.
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.
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)
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.
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
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
FIRE WATER MONITORS
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
FIRE WATER MONITORS  Applicable Standard  IS8442  Water Monitor Flow
FIRE WATER MONITORS
FIRE WATER MONITORS
FIRE WATER MONITORS  High Volume Long Range Water Monitor
FIRE WATER MONITORS  Tower Monitors
FIRE WATER SPRAY SYSTEM
FIRE WATER SPRAY SYSTEM
FIRE WATER SPRAY SYSTEM  Spray System can be,  Medium Velocity Spray System  High Velocity Spray System  Actuation of Spray System can be,  Automatic  Manual
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
FIRE WATER SPRAY SYSTEM  Spray System Components : Deluge Valve Assembly
FIRE WATER SPRAY SYSTEM
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.
FIRE WATER SPRAY SYSTEM Sensing Line Supply Sensing Line To Equipment
FIRE WATER SPRAY SYSTEM Sensing Line QB Bulb
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)
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.
FIRE WATER SPRAY SYSTEM Spray System Design
FOAM SYSTEM
FOAM SYSTEM Foam System  Fixed Foam System  Semi Fixed Foam System  Water-cum-Foam Monitor
FOAM SYSTEM Fixed Foam System
FOAM SYSTEM Fixed Foam System
FOAM SYSTEM Fixed Foam System
FOAM SYSTEM Fixed Foam System  Foam Pump  Bladder Tank  Proportionator  Piping  Material of construction  Actuation  Automatic (Through Detection System)  Manual
FOAM SYSTEM Fixed Foam System
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.
FOAM SYSTEM Semi Fixed Foam System
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.
FOAM SYSTEM Water cum Foam Monitor
FOAM SYSTEM Water cum Foam Monitor
FOAM SYSTEM Portable Foam Trolley
PASSIVE FIRE PROTECTION
PASSIVE FIRE PROTECTION  Fire Proofing  Layout and Safe Distance  Dykes and Drain  Prevention of Ignition (Area Classification)
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
PASSIVE FIRE PROTECTION Fire Proofing
BUILDING FIRE PROTECTION
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
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
BUILDING FIRE PROTECTION Check for Applicable Standards and Regulations  National Building Code  International Building Code  Factory Rule  Fire Rule  Country / State Specific Regulations
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)
BUILDING FIRE PROTECTION Table-7 in NBC
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.
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
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.
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
DRY SPRINKLER
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
BUILDING FIRE PROTECTION Sprinkler Nozzles
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.
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
FIRE EXTINGUISHER
FIRE EXTINGUISHER Types  Water  Foam  Dry Powder  Carbon Dioxide
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
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
FIRE DETECTORS & ALARM Type of Fire Detectors  QB Sensors  Heat Detectors  Point Detector  Linear Detector  Flame Detectors  Smoke Detectors
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
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
THANK YOU !!!!
Fire Protection Training_QPS_26DEC20_Final.pptx

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Fire Protection Training_QPS_26DEC20_Final.pptx

  • 1.
    FIRE PROTECTION TRAINING AT QPS,VADODARA By Abhijit Haldankar 26.10.2020
  • 2.
    Abhijit Haldankar BE ChemicalEngg. (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 : AbhijitHaldankar  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  FireIncident  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
  • 5.
    SAFETY CONTACT  FireIncident  Videos 2, 3
  • 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
  • 7.
    AGENDA  Building FireProtection  Fire Extinguishers  Fire Detection & Alarm System
  • 8.
  • 9.
     What isfire ?  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 ofFire  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
  • 14.
     Fire Triangle Fuel  Heat / Ignition  Oxygen FIRE- BASICS
  • 15.
  • 16.
     Understand theflammable 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 FireProtection  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 FireProtection  Spacing & Layout  Fireproofing  Containment & Drainage  Fire Walls  Hazardous Area Classification FIRE PROTECTION FUNDAMENTALS
  • 19.
  • 20.
    For Process PlantArea  Indian Standard  TAC  NFPA  OISD  API For Buildings  National Building Code  International Building Code  International Fire Code FIRE PROTECTION REGULATIONS & STANDARDS
  • 21.
    Regulations  Factory Act Factory Rule (e.g. Gujarat Factory Rule)  Fire Rule (e.g. Maharashtra Fire Rule)  Petroleum Rule  SMPV Rule  Oil Mining Regulation (OMR) 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
  • 24.
  • 25.
    Remember the “FireProtection 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 youunderstand 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 youunderstand 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 SystemDesign 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 SystemDesign 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 SystemDesign 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
  • 31.
  • 32.
     Single FireScenario / Double Fire Scenario  Demand based on number of hydrants points  Demand for Spray System FIRE WATER DEMAND CALCULATION
  • 33.
    Demand Based onnumbers 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 Capacityas per TAC & IS (12469) FIRE WATER DEMAND CALCULATION
  • 35.
    FIRE WATER DEMANDCALCULATION  Pump Capacity as per TAC & IS (12469)
  • 36.
    FIRE WATER DEMANDCALCULATION  FW Storage Capacity as per TAC & IS (12469)
  • 37.
    FIRE WATER DEMANDCALCULATION  Example
  • 38.
    FIRE WATER DEMANDCALCULATION 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 DEMANDCALCULATION 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 DEMANDCALCULATION 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 DEMANDCALCULATION 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
  • 42.
  • 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
  • 46.
     Suction Strainer Isolation Valve(Other than butterfly Valve) Foot Valve (For negative suction) Priming Arrangement (For Negative suction) Pressure Gauge  Discharge Pressure Gauge Isolation Valve NRV FIRE WATER PUMPS - FITTINGS
  • 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 Jockeypump 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
  • 51.
    FIRE WATER PUMPS FW Pump panel
  • 52.
  • 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
  • 55.
  • 56.
    FIRE WATER NETWORK FireWater Network consists of following,  Fire Water Mains , Sub Headers and Risers  Hydrants  Monitors  Hose Reels  Spray System  Foam System
  • 57.
  • 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
  • 64.
  • 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
  • 66.
    FIRE WATER MONITORS Applicable Standard  IS8442  Water Monitor Flow
  • 67.
  • 68.
  • 69.
    FIRE WATER MONITORS High Volume Long Range Water Monitor
  • 70.
  • 71.
  • 72.
  • 73.
    FIRE WATER SPRAYSYSTEM  Spray System can be,  Medium Velocity Spray System  High Velocity Spray System  Actuation of Spray System can be,  Automatic  Manual
  • 74.
    FIRE WATER SPRAYSYSTEM 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 SPRAYSYSTEM  Spray System Components : Deluge Valve Assembly
  • 76.
  • 77.
    FIRE WATER SPRAYSYSTEM 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 SPRAYSYSTEM Sensing Line Supply Sensing Line To Equipment
  • 79.
    FIRE WATER SPRAYSYSTEM Sensing Line QB Bulb
  • 80.
    FIRE WATER SPRAYSYSTEM 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 SPRAYSYSTEM 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.
  • 82.
    FIRE WATER SPRAYSYSTEM Spray System Design
  • 83.
  • 84.
    FOAM SYSTEM Foam System Fixed Foam System  Semi Fixed Foam System  Water-cum-Foam Monitor
  • 85.
  • 86.
  • 87.
  • 88.
    FOAM SYSTEM Fixed FoamSystem  Foam Pump  Bladder Tank  Proportionator  Piping  Material of construction  Actuation  Automatic (Through Detection System)  Manual
  • 89.
  • 90.
    FOAM SYSTEM Semi FixedFoam 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.
  • 91.
  • 92.
    FOAM SYSTEM Water cumFoam 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.
  • 93.
  • 94.
  • 95.
  • 96.
  • 97.
    PASSIVE FIRE PROTECTION Fire Proofing  Layout and Safe Distance  Dykes and Drain  Prevention of Ignition (Area Classification)
  • 98.
    PASSIVE FIRE PROTECTION FireProofing  Applicable Standard  OISD164  API2218  Fire Potential Equipment  Any Equipment Handling Liquid Hydrocarbon or Liquefied Gas  Fire Hazardous Area  General Requirement of fireproofing  Duration  Temperature
  • 99.
  • 100.
  • 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 Checkfor 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)
  • 105.
  • 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 FireProtection For Buildings  Riser or Down comers with Hydrants  Yard Hydrants  Hose Reels  Fire Extinguishers  Automatic Sprinkler  Smoke Detectors  Heat Detectors
  • 108.
    BUILDING FIRE PROTECTION SprinklerRequirement 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
  • 110.
  • 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
  • 112.
  • 113.
    HOSE REEL  Hosereel 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  FireExtinguishers 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
  • 115.
  • 116.
    FIRE EXTINGUISHER Types  Water Foam  Dry Powder  Carbon Dioxide
  • 117.
    FIRE EXTINGUISHER DCP FireExtinguisher 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
  • 122.