OISD-STANDARD-189 August, 2000

STANDARD ON FIRE FIGHTING EQUIPMENT FOR DRILLING RIGS, WORK OVER RIGS AND PRODUCTION INSTALLATIONS

Prepared by : Committee on " Standard on fire fighting equipment for Drilling rigs, Work over rigs and Production installations"

OIL INDUSTRY SAFETY DIRECTORATE 2ND FLOOR , KAILASH 26, Kasturba Gandhi Marg, NEW DELHI-110001

Committee on " Standard on fire fighting equipment for Drilling rigs, Work over rigs and Production installations".

SN .

NAME

ORGANISATION

POSITION IN THE COMMITTEE Leader Co-ordinator Member Member

1 2. 3 4.

Sh. P.S.Narayanan Sh. Gulab Singh Sh. Neeraj Sharma Sh. V.S.Kumar

Oil India Limited OISD ONGC ONGC

FOREWORD The purpose of this standard is to assist the oil industry in prevention of fire incidents. It is recognised that the provision indicated in the standard cannot possibly cover all the problems which may arise during the operation. However provision indicated in the standard will definitely help in reducing the major fire hazards in oil industry. Employees available at site should always be kept alert to unforeseen hazards and changing conditions will present new exposures, which must be met with appropriate precautions. The standard will however, assist each individual worker to improve his work methods and reduce accidents.

Suggestions are invited from the users after it is put into practice to improve the document further. Suggestions for amendments to this document should be addressed to:

The Coordinator Committee on" Standard on fire fighting equipment for Drilling rigs, Work over rigs and Production installations".

OIL INDUSTRY SAFETY DIRECTORATE KAILASH, 2ND FLOOR 26, K.G. MARG NEW DELHI 110 001

The standard in no way supersedes the statutory requirements of bodies like DGMS, CCE or any other Government Body which must be followed as applicable.

NOTE

OISD publications are prepared for use in the oil and gas industry under Ministry of Petroleum & Chemicals. These are the property of Ministry of Petroleum & Chemicals and shall not be reproduced or copied and loaned or exhibited to others without written consent from OISD. Though every effort has been made to assure the accuracy and reliability of the data contained in this documents. OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from their use. These documents are intended to supplement rather than replace their prevailing statutory requirements.

CONTENT

SECTION 1. 2. 3. 4. 5. 6. 7.

DESCRIPTION Introduction Scope Definitions Fire protection philosophy Fire fighting system -Drilling Rig Fire fighting system - WOR Fire fighting system- Production Installation GGS/OCS

PAGE NOS. 1 1 1 2 2 4 6

8. 9. 10. 11. 12. 13. 14. 15. 16.

Fire fighting system- GCP/GCS Fire fighting system- EPS Fire fighting system- QPS/WHI Material Specifications Fire Alarm and communications Fire safety organisation/Training Fire emergency manual Fire protection system inspection and testing References

10 12 13 14 14 14 15 15 15

FIRE PROTECTION FACILITIES FOR DRILLING RIGS, WORKOVER RIGS, GROUP GATHERING STATIONS/OIL COLLECTING STATIONS, GAS COMPRESSOR PLANTS/GAS COMPRESSOR STATIONS, EARLY PRODUCTION SET-UP AND QUICK PRODUCTION SET-UP/ WELL HEAD INSTALLATION 1.0 INTRODUCTION
2.3 In the upstream petroleum industry companies are engaged in exploration and development of oilfields as well as production of crude oil and gas. It has been observed that most of the activities like drilling operation, setting up of GGS/OCS, GCP/GCS etc. are carried out initially at remote areas away from the thickly populated locality. However, once the field is established, it has been observed that the area gets surrounded by population and small industries. These causes hazards to the oilfield installations as well as to surrounding residents. For the protection of the costly equipment and the safety of the surrounding areas, it is important to install necessary in-built fire protection arrangement in the installations. It would be highly costly affair to build systems to control oil well blowout fire or any catastrophic fire situation at each drill site. Here in the standard, necessary minimum fire protection arrangements which are required to fight initial fire in the oilfield installations, workover rigs(WOR) and drilling rigs were included. However, while making the system, due consideration should be given to the availability of nearby city as well as industrial fire services. It may not be possible to build/incorporate all these fire fighting systems in the existing oilfield installations which are already approved by the respective statutory authority long back. However, it is desirable to incorporate certain fire fighting system in these old installations as and where practicable and acceptable to the management. This standard does not cover plants processing Liquefied Petroleum Gas (LPG) handling, storage or bottling areas. The same are covered in OISD-STD-144, 116 OR 169 as the case may be.

3.0
3.1

DEFINITIONS
DRILLING RIG

Drilling Rig is a compact unit including derrick structure,power generating unit for running the draw-works, mud preparation unit and all other necessary equipment for carrying out drilling operation of the earths surface by mechanical means to reach down to the oil bearing zones below the ground for exploration and development of oil and gas field. 3.2 WORKOVER RIG

Workover Rig is a compact mobile unit along with some other external equipment for mud preparation and power generation etc. The whole unit is mainly required for oil/gas well servicing by performing variety of remedial operation on an oil/gas well as per the technical requirement with the intention of restoring or increasing production.

3.3 GROUP GATHERING STATION/OIL COLLECTING STATION It is a production installation where production from number of wells are collected together for treating and separating oil, water & gas for further despatch to central tank farm. 3.4 GAS COMPRESSION PLANT/GAS COMPRESSOR STATION It is an installation where gases are collected from GGS/OCS and are compressed to different pressures for transportation..

2.0

SCOPE

2.1 This standard covers certain design criteria and minimum requirement of fire protection facilities at drilling rigs, workover rigs and production installations (GGS/OCS, GCP/GCS, EPS, QPS/WHI etc). 2.2 This standard does not cover fire protection facilities of refineries, petroleum depots, terminals or any other gas processing plant for which OISD - STD - 116 should be referred to. 1

3.5 (EPS)

EARLY

PRODUCTION

SET

UP

4.2

Design criteria

It is a production installation similar to GGS or OCS in nature; however, very small in capacity. This type of set up is generally installed at a very early stage of development of any oilfield area when the number of wells are limited and their total production is also very less. 3.6 QUICK PRODUCTION SET (QPS)/ Well Head Installation(WHI) UP

Design criteria of any fire fighting system would depend upon the type of installation involved. Following shall be the basic design criteria for a fire protection system. I) In drilling and workover rigs, fire water storage/fire protection system should be designed to initiate the fire fighting operation before the mobile fire tenders reach at site to provide back up service for prolonged period. II) In CTF/GGS/OCS and GCP/GCS fire protection, facilities shall be designed to fight one major fire within the installation. III) In EPS, QPS and WHI minimum fire protection facilities shall be designed to initiate the fire fighting operation before the mobile fire tenders reaches at site to provide back up service for prolonged period. IV) All the areas except QPS/WHI shall be covered with hydrants and water monitors. V) Foam system should be provided for storage tank (fixed/floating roof) protection at CTF/GGS /OCS. All storage tanks (fixed/floating roof) at CTF/GGS/OCS having capacity more than 500 KL and diameter more than 9.0 metres should be protected with water spray/drenching system. Fire fighting equipment shall be provided at all installations CTF/GGS/OCS as per section 70 (2) & (3) OMR-84. A water ring main with adequate storage of water at site, pump feeding hydrants and water monitors shall be provided and maintained. Fixed roof storage tank shall be provided with fixed foam connections.

It is a production installation, generally set up in case of extremely new oildfield area and its capacity is further smaller compared to any EPS.

4.0 FIRE PROTECTION PHILOSOPHY

Activities involved in exploration and production of crude oil are extremely risky and may cause considerable financial burden for the industry if any fire / exploration occurred in a drilling or any other installation. Hence, emphasis should be given to design minimum fire protection facilities at various drilling and other production installations, so that in case of fire, it can be Extinguished at its incipient stage to minimise the loss of life and property and also to prevent further spread of fire. 4.1 GENERAL CONSIDERATIONS

VI)

VII) All drilling and workover rigs are riggedup for short duration and activities are similar in nature therefore basic fire protection facilities and design criteria would be similar in nature. However, for GGS/OCS, GCP/GCS, EPS & QPS/WHI, fire protection facilities would depend upon the size/capacity of the plant and its layout. Layout of the plant shall be done in accordance with the relevant OISD Standard (Std.118 on Layouts). A good layout can minimise fire risk hazard by providing adequate fire fighting access, means of escape in case of fire and also isolation/segregation of risks / facilities, so that nearby facilities are not affected during a fire incident. In this regard, safe distance from various hazards to installations mentioned in OMR-1984 may be referred. The following fire protection facilities shall be provided according to various categories of installations and risks associated therein: Fire Water system Foam system First Aid fire fighting equipment Communication systems, etc. 2

5.0 FIRE FIGHTING SYSTEM/EQUIPMENT AT DRILLING RIG In drilling rig following fire fighting system/equipment should be provided: Fire water system First aid fire fighting system

5.1

Fire Water System In drilling rig minimum fire water system should be considered to initiate the fire fighting operation at the incipient stage and before the arrival of the mobile fire tenders.

5.1.1

Components of fire water system

The main components of fire water system are fire water storage, fire water pumps and distribution network. 5.1.2 Criteria

The fire water system in a drilling rig should be designed to meet the fire water flow required for fighting fire with a monitor of minimum 1600 LPM capacity. However, provision should be made in the system to hook up from the mobile fire tender or any other water supply of adequate pressure to operate some additional water monitors etc. 5.1.3 Water Storage

distance of 15.0 metres from the well head area. The water line should be charged from the delivery of the trailer fire pump and also provision shall be made to charge the line from the outside fire tender/pump. ii) Hydrants Hydrants in the line should be located in such a manner that the entire hazardous areas are covered/protected. At least 2 nos. of hydrants should be provided on the line (one near bunk houses and other near generator area). Single hydrant with landing valves and 4 stand post shall be provided. All hydrant outlets shall be situated 1.2 mtrs above the ground level.

iii)

One water tank of capacity minimum 50 KL should be installed at the approach site of the drilling location. The tanks should be skid mounted welded type with adequate thickness. Provision should be made to divert the water available for mud preparation purpose to the fire water storage tank if required during any emergency. Water filling arrangement for the tank should be made. In exploratory well drilling, one additional tank/pit of 40 KL to be provided.

Monitors Water monitors fixed/portable shall be installed/provided at least 15.0 mtrs. away from the well head. Monitors shall be located to direct the water jet on the well head and other hazardous area and also to provide water shield to the fireman approaching a fire. The location of the monitors shall not exceed 30.0 mtrs. from the derrick area to be protected. iv) Minimum four numbers of fire hoses with two numbers of branch pipes should be provided at site.

5.1.4

Fire Water Pump

5.2 FIRST AID FIRE FIGHTING EQUIPMENT AT DRILLING RIG 5.2.1 Portable Fire Extinguisher Portable fire Extinguisher should be installed as per the IS-2190 . All the Extinguisher should be located at a convenient location and clearly visible and easily accessible. Maximum running distance from any point to the nearest Extinguisher shall not exceed 10.0 metres. The portable Extinguisher shall be installed in such a way that the top of the Extinguisher is not more than 1.5 mtrs above the floor level.

One diesel engine driven trailer fire pump of capacity 1800 LPM should be placed at the approach area of a drilling site. The pump should be capable of developing 7.0 kg/cm2 pressure and it should be hooked up with the water storage tank provided at the approach area. 5.1.5 Fire Water Distribution Line

i) One fire water distribution single line with minimum 4 size pipe/casing should be installed at the drilling rig with a minimum

The minimum quantities of fire Extinguisher at various locations should be provided as per the followings: Type of Area Derrick floor Portable Extinguisher 2 nos. 10 kg DCP Extinguisher 1 No. 10 kg DCP Extinguisher for each engine 1 No. 10 kg DCP Extinguisher

i) ii)

Main Engine area (catterpillar Engine 3 nos.) Electrical motor/pump for water circulation for mud preparation Mud gunning pump area -

iii)

iv)

1 No. 10 kg DCP Extinguisher for each mud gunning pump 3

v)

Electrical Control Room -

vi) vii)

Mud mixing tank area/ Chemical laboratory Diesel storage area

1 No. 6.8 kg CO2 Extinguisher for each unit 1 No. 10 kg DCP Extinguisher for each unit 1 No. 10 kg DCP Extinguisher 1 No. 50 ltrs Mechanical foam Extinguisher 1 No. 50 kg DCP Extinguisher 2 Nos. 10 kg DCP Extinguisher 2 Nos. sand bucket or 1/2 sand drum with spade. 1 No. 10 kg DCP Extinguisher 1 No. Sand bucket stand 1 No. 10 kg DCP Extinguisher 1 No. 10 kg DCP Extinguisher 1 No. Fire Extinguisher/Shed with 3 Nos. 10 kg DCP Extinguisher and 2 Nos. sand bucket. 1 No.

viii) ix) x) xi)

Lube storage area Air compressor area Fire pump area Near DIC office

xii)

Fire bell near bunk house -

FIRE FIGHTING FACILITIES AT WORKOVER RIG

6.0 In Workover Rig following fire fighting arrangement should be made: - Fire water storage facilities with fire pump - Portable fire Extinguisher

6.1

Fire Water Storage with fire pump

One 40.0 KL capacity water storage tank should be provided at the approach area and it should be connected with a trailer/skid mounted diesel engine driven fire water pump of capacity 1800 LPM at 7.0 kg/cm2 pressure. The water storage tank should be skid mounted welded type of adequate thickness. Minimum 4 hydrant line/Hoses to cover well head and hazardous area form approach side(Single line) should be

provided with one monitor and one hydrant point. One point near approach should be provided for connecting fire tender. Tank available for preparation of well work over fluid can also be used for fire fighting purpose, provided it is kept at safe place and always kept full. One additional TPC connection should be provided with the fire water storage tank for connection of the fire tender in case of emergency. Regular filling arrangement of the above mentioned tank should be provided. Necessary hose storage facilities should be provided for keeping 4 nos. Fire hose of full length with 2 nos. branch pipe. In case more number of WORs are operating in same area and fire fighting facilities are available within 15 minutes from nearby GGS/CTF/WOR/Drilling rig than pumps and water tankers can be pooled suitably for WORs so that resources are available during critical operations.

6.2

First Aid Fire Fighting Equipment at Workover Rig Type of Area Portable Extinguisher 1 No. 10 kg DCP Extinguisher 1 No. 10 kg DCP Extinguisher 2 No. 10 kg DCP Extinguisher 1 No. 10 kg DCP Extinguisher 1 No. 6.8 kg CO2 Extinguisher 1 No. 10 kg DCP Extinguisher 4

I) ii) iii) iv)

Workover rigs engine area Rigs compressor area Rig floor area Electrical generator house

v)

Mud Water Pump/motor area

vi) vii) viii)

Near DIC office area Fire bell near office cabin Lub. Oil area

2 No. 10 kg DCP Extinguisher 2 Nos. Sand bucket 1 2 No. 10 kg DCP Extinguisher 2 Nos sand bucket

Note: Sufficient safety precaution should be taken while transporting the Extinguisher from location to location.

7.0 FIRE FIGHTING FACILITIES IN CTF/GGS/OCS

The fire fighting facilities in CTF should be done as per OISD Standard 117. 7.1 FIRE WATER SYSTEM

and situated in the same dyke at a rate of 1 lpm/m2 of tank shell area. Water flow required for applying foam on a single largest tank by way of fixed foam system, where provided, or by use of water/foam monitors.

Water is an essential and the most important medium available to mankind for fire protection. Water is used for fire extinguishment, fire control, cooling of equipment, exposure protection of equipment and personnel from heat radiation. For these purposes water is used in various forms such as straight jet, water fog, water curtain, water spray, deluge / sprinkler, oscillating monitors for foam preparation etc. 7.1.1 Components of Fire Water System

7.1.3

HEADER PRESSURE

The fire water pressure system shall be designed for a minimum residual pressure of 7 kg/cm2g at the hydraulically remotest point of application at the designed flow rate at that point.

7.1.4

STORAGE

The main components of the system are Fire Water Storage, Fire Water Pumps and Distribution Piping Network. 7.1.2 Basis :

The fire water system in an installation should be designed to meet the fire water flow required for fighting one largest risk at a time. DESIGN FLOW RATE: Fire water flow rate for a tank farm shall be aggregate of the following: Water flow calculated for cooling a tank on fire at a rate of 3 lpm/m of tank shell area. Water flow calculated for exposure protection for all other tanks falling within a radius of (R +30)m from centre of the tank on fire (R-Radius of tank on fire) and situated in the same dyke at a rate of 3 lpm/m of tank shell area. Water flow calculated for exposure protection for all other tanks falling outside a radius of (R+30)m from centre of the tank on fire 6

Water for the hydrant service shall be stored in any easily accessible surface or underground lined reservoir or above ground tanks of steel concrete or masonry. The effective capacity of the reservoir / tank above the level of suction point shall be minimum 2 hours aggregate working capacity of pumps. Make up water supply source shall be ensured. Fire water supply shall be preferably from fresh water source such as river, tubewell or lake. Where fresh water source is not easily available, fire water supply may be sea water or other acceptable source like treated effluent water. Where treated effluents is used as fire water supply, it shall not have fecal waste contamination. The installation shall have facilities for receiving and diverting all the water coming to the installation to fire water storage tanks in case of an emergency. Storage reservoir shall be in two equal interconnected compartments to facilitate cleaning and repairs. In case of steel tanks there shall be minimum two tanks each having 50 % of required capacity.

Large natural reservoirs having water capacity exceeding 10 times the aggregate water requirement of fire pumps may be left unlined.

affecting the flow in the rest. The isolation valves shall be located normally near the loop junctions. Additional valves shall be provided in the segments where the length of the segment exceeds 300 mtrs. (ii) Above / Underground Network :

7.1.5

FIRE WATER PUMPS

Fire water pumps shall be installed to meet the design fire water flow rate and head. These should have flooded suction. 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 for horizontal centrifugal pumps and 140% for vertical turbine pump. A minimum of 50% standby pump(s) (minimum one no.) of the same type and capacity as the main pumps shall be provided. The fire water pump(s) including the standby pump(s) shall be of diesel engine driven type. Where electric supply is reliable 50% of the pumps may be electric driven. The diesel engines shall be quick starting type with the help of push buttons located on or near the pumps or located at a remote location. Each engine shall have an independent fuel tank adequately sized for 6 hours continuous running of the pump. Fire water pumps & storage shall be located at 30 mtrs (minimum) away from equipment or where hydrocarbons are handled or stored. Fire water pumps shall be exclusively used for fire fighting purpose only. The fire water network shall be kept pressurised by a static tank or jockey pump(s). Where jockey pumps are used, the capacity of pump shall be sufficient to maintain the system pressure in the event of leakages from valves etc. The capacity of Jockey pump shall not be less than 3% (with a minimum of 180 lpm) and not more than 10% of the designed fire water rate at network pressure not less than 3 Kg/cm2g.

The fire water network piping should normally be laid above ground at a height of 300 mm to 400 mm above finished ground level. However, the fire water network piping shall be laid below ground level at the following places Road crossings. Places where the above ground piping is likely to cause obstruction to operation, vehicle movement and places where the above ground piping is likely to get damaged mechanically. Where frost condition warrants, the pipeline shall be laid under-ground beneath the frost layer. (iii) Protection of underground pipelines:

- The mains shall have at least one mtr. earth cushion in open ground and 1.5 mtrs cushion under the roads. In case of crane movement areas, pipe may be protected with concrete/steel encasement. - The mains shall be provided with protection against soil corrosion by suitable coating/wrapping. In case of poor soil conditions it may be necessary to provide concrete/masonry supports under the pipe. Protection of above ground pipes: - The mains shall be supported at regular intervals not exceeding 6 mtrs. - The system for above ground portion shall be analysed for flexibility against thermal expansion and necessary expansion loops where called for shall be provided. (iv) SIZING:

7.1.6

FIRE WATER DISTRIBUTION NETWORK Looping:

(i)

The fire water network shall be laid in closed loops as far as possible to ensure multi-directional flow in the system. Isolation valves shall be provided in the network to enable isolation of any section of the network without 6

Fire water distribution ring main shall be sized for 120% of the design water rate. Design flow rates shall be distributed at nodal points to give the most realistic way of water requirement in an emergency. It may be necessary to assume several combinations of flow requirement for design of network. For large water requirement for floating roof tank the network around the tank

farm shall be suitably designed. The analysis of network shall be preferably done through a computer programme. The minimum residual pressure shall be as defined in 7.1.3. v) The fire water network shall always be kept pressurised by any of the following arrangements: If fire water is stored in above ground storage tanks with water level more than 5 mtrs. above the highest point of fire water network, a direct connection with a non-return valve shall be provided to the fire water network from the storage tank. If the fire water is stored in underground tanks, the fire water network shall be connected to an overhead water tank if available in the installation; otherwise a jockey pump shall be installed to keep the mains pressurised. Make up water shall be provided to account for leakages in the system so that fire water storage is kept to the desired capacity. (vi) Connections for fixed water monitors shall be provided with independent isolation valves. (vii) Fire water mains shall not pass through buildings or dyke areas. (viii) In case of underground mains the isolation valves shall be located in RCC/brick masonry chamber.

building. Provision of hydrants within the building shall be provided in accordance with IS : 3844. Hydrant/Monitors shall be located along road side for easy accessibility. (iii) Double headed hydrants with two separate landing valves on 4" standpost shall be used. All hydrant outlets shall be situated 1.2 mtrs. above ground level. (iv) Monitors shall be located to direct water on the object as well as to provide water shield to firemen approaching a fire. Monitors shall not be installed less than 15mtrs. from hazardous equipment. The requirement of monitors shall be established based on hazards involved and layout considerations. The location of the monitors shall not exceed 45 mtrs from the hazard to be protected. (v) Hydrants and monitors shall not be installed inside the dyke areas. However, as an additional requirement, oscillating monitors may be provided in inaccessible area within dyke with isolation valve or ROV outside the tank farm. (vi) Tanker Loading/unloading area should be provided with alternate water cum foam monitors having multipurpose combination nozzles for jet spray & fog arrangement and fire hydrants located at a spacing of 30 mtrs. on both sides of the gantry. The hydrants & monitors shall be located at a minimum distance of 15 mtrs. from the Tanker. (vii) Hydrants/Monitors shall be preferably located with branch connection.

7.1.7

HYDRANTS AND MONITORS: 7.1.8 FIXED WATER SPRAY SYSTEM

(i) Hydrants shall be located bearing in mind the fire hazards at different sections of the premises to be protected and to give most effective service. At least one hydrant post shall be provided for every 30 mtrs of external wall measurement or perimeter of battery limit in case of high hazard areas. For non-hazardous area, they shall be spaced at 45 mtrs. intervals. The horizontal range & coverage of hydrants with hose connections shall not be considered beyond 45 mtrs. (ii) Hydrants shall be located at a minimum distance of 15 mtrs. from the periphery of storage tank or equipment under protection. In case of buildings this distance shall not be less than 2 mtrs. and not more than 15 mtrs. from the face of 7

(i) Fixed spray water system is a fixed pipe system connected to a reliable source of water supply and equipped with water spray nozzles for specific water discharge and distribution over the surface of area to be protected. The piping system is connected to the hydrant system water supply through an automatically or manually actuated valve, which initiates the flow of water. (ii) Water supply patterns and their densities shall be selected according to need. Fire water spray system for exposure protection shall be designed to operate before the possible failures of any containers of flammable liquids or gases due to temperature rise. The system shall, therefore, be designed to discharge effective water spray within shortest possible time.

7.2

FOAM SYSTEMS

(i) System be designed to create foam blanket on the burning surface in a reasonably short period. (ii) Foam shall be applied to the burning hazard continuously at a rate high enough to overcome the destructive effects of radiant heat. (iii) Foam makers/foam pourers shall be located not more than 24 mtrs. apart on the shell perimeter based on 600 mm foam dam height. (iv) A minimum of two foam pourers shall be provided.

7.2.1

CONVEYING SYSTEMS

The system consists of an adequate water supply, supply of foam concentrate, suitable proportioning equipment, a proper piping system, foam makers and discharge devices designed to adequately distribute the foam over the hazard. Conventional systems are of the open outlet type, in which foam discharges from all outlets at the same time, covering the entire hazard within the confines of the system. There are three types of systems: i) ii) iii) (i) Fixed Semi-Fixed Mobile

7.2.3

FIXED ROOF TANK PROTECTION

Foam conveying system shall have same features as of floating roof tank excepting that a vapour seal chamber is required before the foam discharge outlet. Features of the foam system for fixed roof protection shall be as follows: (i) The vapour seal chamber shall be provided with an effective and durable seal, fragile under low pressure, to prevent entrance of vapour into the foam conveying piping system. (ii) Where two or more pourers are required these shall be equally spaced at the periphery of the tank and each discharge outlet shall be sized to deliver foam at approximately the same rate. (iii) Tanks should be provided with foam discharge outlets/pourers as indicated below: Tank Diameter in mtrs. >18 >20 >25 >30 >35 >40 >45 upto upto upto upto upto upto upto 20 25 30 35 40 45 50 Minimum number of foam discharge outlet 2 3 4 5 6 8 10

Fixed Foam System

Fixed foam conveying system comprises of fixed piping for water supply at adequate pressure, foam concentrate tank, eductor, suitable proportioning equipment for drawing foam concentrate and making foam solution, fixed piping system for onward conveying to foam makers for making foam, vapour seal box and foam pourer. (ii) Semi-Fixed Foam System

Semi-fixed foam system gets supply of foam solution through the mobile foam tender. A fixed piping system connected to foam makers cum vapour seal box in case of cone roof tanks and foam maker and foam pourers in the case of floating roof tanks conveys foam to the surface of tank. (iii) Mobile System

Mobile system includes foam producing unit mounted on wheels, which may be self propelled or towed by a vehicle. These units supply foam through monitors/foam towers to the burning surface. 7.2.2 FLOATING ROOF TANK PROTECTION For floating roof tank, foam shall be poured at the foam dam to blanket the roof seal. Features of foam system for floating roof tank protection shall be as follows:

The estimation of number of foam discharge outlet is based on pourer capacity of 1000 lpm at a pressure of 7 kg/cm2 g upstream of eductor.

7.2.4

FLOATING CUM FIXED ROOF TANK PROTECTION

shall be used for determining water quantity required.

Protection facilities shall be provided as required for fixed roof tank. 7.2.5 PROTECTION FOR DYKE AREA/SPILL FIRE

7.2.9

FOAM QUANTITY REQUIREMENT

The aggregate quantity of foam solution should be calculated as below : (i) Foam solution application at the rate of 5 lpm/m2 for the liquid surface of the single largest cone roof tank or at the rate of 12 lpm/m2 of seal area of the single largest floating roof tank whichever is higher. However, a foam solution application rate of 8.1 lpm/m2 of the liquid surface of the largest floating roof tank for 65 minutes may be considered for a roof sinking case. (Refer Annexure-IV for sample calculation) (ii) Two hose streams of foam each with a capacity of 1140 lpm of foam solution. The aggregate quantity of foam solutions should be largest of (i) and (ii) as above for a minimum period of 65 minutes. From this the quantity of foam based on 3% or 6% proportion should be calculated.However, for installation having aggregate storage not more than 10,000 KL, the foam concentrate storage shall be based on (i) only.

Portable monitors/foam hose streams shall be considered for fighting fires in dyke area and spills. 7.2.6 FOAM APPLICATION RATE

The minimum delivery rate for primary protection based on the assumption that all the foam reaches the area being protected shall be as indicated below : For cone roof tanks containing liquid hydrocarbons, the foam solution delivery rate shall be at least 5 lpm/m2 of liquid surface area of the tank to be protected. For floating roof tanks containing liquid hydrocarbons foam solution delivery rate shall be at least 12 lpm/m2 of seal area with foam dam height of 600 mm of the tank to be protected. In case of floating roof sinking, the rate considered should be 8.1 lpm/m2 of liquid surface areas. In determining total solution flow requirements, potential foam losses from wind and other factors shall be considered. 7.2.7 DURATION OF FOAM DISCHARGE The equipment shall be capable of providing primary protection at the specified delivery rates for the following minimum period of time. i) Tanks containing Class 'A' & 'B'

7.2.10

FOAM COMPOUND STORAGE

Foam compound should be stored in plastic containers of 20-30 ltrs capacity or 200/210 ltrs capacity barrels in case of protein, fluroprotein or AFFF. Foam compound can also be stored in overhead storage tank of suitable capacity for quick filling of foam tender/nurser during emergency. Type of foam compound used can be protein or fluroprotein or AFFF. Alcohol Resistant Foam can be used for specific application. Minimum life of foam compound shall be taken as per manufacturer's data. Foam compound shall be tested periodically for ensuring its quality and the deteriorated quantity replaced. The deteriorated foam compound can be used for fire training purposes. Quantity of foam compound equal to 1000 Ltrs. to be kept in GGS/OCS . Additional quantity required if any, during emergency shall be arranged from the near by installations/ CTF. 9

65 minutes

ii)

Where the system's primary purpose is for spill fire protection -

30 minutes

7.2.8

WATER FOR FOAM MAKING

Water quantity required for making foam solution depends upon the type of foam used. Protein foams in normal use have a 3% to 6% proportioning ratio. However, foam supplier data

7.3 The minimum quantities of fire Extinguishers at various locations in GGS/OCS should be provided as per following : AREA Separator Area Dispatch Pump area Manifold Area Storage Tank Area Generator House Area Fire Pump Area Tanker Loading /unloading pt. PORTABLE EXTINGUISHER For every 50.0 m2 one DCP Extinguisher 1 No. 10 kg DCP / Pump 2 No. 10 kg DCP/ manifold 6 Nos. 10 kg DCP + 1 No. 50 kg DCP 1 No. 6.8 kg CO2 Extinguisher. & 1 No. 10 kg DCP Extinguisher. 1 No. 10 kg DCP Extinguisher. 3 Nos. 10 kg DCP 1 No. 50 kg DCP 1 No.50 ltr. Mechanical Foam Extinguisher. 3 Nos. 10 kg DCP Extinguisher. 1/2 cut Drum with sand & sawel 2 Nos. 10 kg DCP Extinguisher. 4 Nos. 6.8 kg CO2 Extinguisher. 2 Nos. 10 kg DCP 1 No. 6.8 kg CO2 Extinguisher. 2 Nos. 10 kg DCP 2 Nos. 10 kg DCP Extinguishers 1 No. 10 kg DCP Extinguisher. 2 Nos. 10 kg DCP Extinguishers.

i) ii) iii) iv) v) vi) vii)

viii) ix) x) xi) xii) xiii) xiv) xv)

Emulsion Treater Area Lub Oil/Fuel Storage Area Switchgear room Boiler Area/Bath heater Chemical dozing pump area Office building area Disposal water pump area Water Clarification plant

8.1.2

BASIS

8.0 FIRE FIGHTING FACILITIES IN GCP/GCS

Following fire fighting arrangement should be made in a Gas Compressor Plant/Gas Compressor Station: Fire water system First Aid fire fighting equipment Detection System and Alarm 8.1.1 FIRE WATER SYSTEM

Gas Compressor Plant is an extra high hazardous installation. Any fire incident may cause major damage to the compressor plant. Hence, system should be capable of handling any major outbreak of fire incident at any Compressor. Design of water flow rate should be enough to operate 2 nos. Water monitor (1600 LPM) simultaneously from the two opposite sides of any Compressor with full working pressure (7.0 kg/cm2).

Water is an essential and the most important medium available to mankind for fire protection. Water is used for fire extinguishment, fire control, cooling of equipment, exposure protection of equipment and personnel from heat radiation. For these purposes water is used in various forms such as straight jet, water fog, water curtain, water spray, deluge / sprinkler, oscillating monitors for foam preparation etc.

8.1.3

Component of fire water system

Main component of fire water system is fire water storage, fire water pump and distribution network.

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8.1.3.1 FIRE WATER STORAGE In almost all cases, Gas Compressor Plants/Stations are situated adjacent to GGS/OCS where good fire water system with adequate water storage and pumping facilities are available. Hence, as much as practicable this system should be hooked up with the GCP/GCSs water ring main to avoid separate water storage and pumping units. Otherwise, separate water storage and pumps should be provided. Minimum 300 K.L. of water storage shall be available at GCS/GCP. Fire water supply shall be preferably from fresh water source such as river, tubewell or lake. Where fresh water source is not easily available, fire water supply may be sea water or other acceptable source like treated effluent water. Where treated effluents is used as fire water supply, it shall not have fecal waste contamination. The installation shall have facilities for receiving and diverting all the water coming to the installation to fire water storage tanks in case of an emergency. Storage reservoir shall be in two equal interconnected compartments to facilitate cleaning and repairs. In case of steel tanks there shall be minimum two tanks each having 50 % of required capacity. Large natural reservoirs having water capacity exceeding 10 times the aggregate water requirement of fire pumps may be left unlined.

centrifugal pumps and 140% for vertical turbine pump. A minimum of 50% standby pump(s) (minimum one no.) of the same type and capacity as the main pumps shall be provided. T h e f i r e water pump(s) including the standby pump(s) shall be of diesel engine driven type. Where electric supply is reliable 50% of the pumps may be electric driven. The diesel engines shall be quick starting type with the help of push buttons located on or near the pumps or located at a remote location. Each engine shall have an independent fuel tank adequately sized for 6 hours continuous running of the pump. Fire water pumps & storage shall be located at 30 mtrs (minimum) away from equipment or where hydrocarbons are handled or stored. Fire water pumps shall be exclusively used for fire fighting purpose only. The fire water network shall be kept pressurised by a static tank or jockey pump(s). Where jockey pumps are used, the capacity of pump shall be sufficient to maintain the system pressure in the event of leakages from valves etc. The capacity of Jockey pump shall not be less than 3% (with a minimum of 180 lpm) and not more than 10% of the designed fire water rate at network pressure not less than 3 Kg/cm2g. 8.1.3.3 Fire Water Distribution Network Fire water ringmain should be made available all around the gas compressor plant. The size of the ringmain should be of 8 diameter. Hydrants and monitors should be provided in the entire ringmain and distance between the two monitors or two hydrants should not exceed 30.0 mtrs. Hydrant and monitors should be located at minimum distance of 15.0 metres from the periphery of compressors or equipment under protection along road side. However, total number of hydrants and monitors should depend upon the number of compressor and the location of each compressor. No area should be left uncovered from the range of the water monitors.

8.1.3.2 FIRE WATER PUMPS i) Fire water pumps shall be installed to meet the design fire water flow rate and head. These should have flooded suction. 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 for horizontal 8.2

First Aid Fire Fighting Equipment at GCP/GCS Type of area Portable Extinguisher 1 No. 10 kg DCP Extinguisher 2 No. 10 kg DCP Extinguisher 1 No. 10 kg DCP Extinguisher 1 No. 50 kg DCP Extinguisher 1 No. 10 kg DCP Extinguisher 11

I) ii) iii) iv)

Near each compressor unit Glycol dehydration unit Air Compressor area Condensate recovery unit

v)

Main electrical switchgear area Both side of the main compressor shed area

1 No. 6.8 kg CO2 Extinguisher 1 No. 10 kg DCP Extinguisher 1 No. 50 kg DCP Extinguisher at each side of the main compressor shed.

vi)

8.3

DETECTION SYSTEM AND ALARM

9.1

Fire Water System

Human beings are excellent fire detectors since they possess sense of smell, sight, and touch. But since human senses are also unreliable due to the need for frequent rest and relaxation, a number of mechanical, electrical and electronic devices have been developed to mimic human senses in the detection of gases / smoke / heat and flame. A flammable gas detector is designed to give a warning of the presence of flammable gases or vapours in air, well before they reach explosive concentrations. Normally, the detector provides visible and audible alarm signals, but frequently it performs a further function by initiating control action such as increasing ventilation or shutting off the source of gas. A flammable gas detector can also be used for tracing leaks and checking that vessels or tunnels are gas free before entering. While designing a fire detection and suppression system for GCP following criteria may also be kept under consideration:1) Gas detection system connected to emergency shut down system on coincident logic. 2) Ultraviolet (UV) detection system or equipment, connected to FSD( Fire Shut Down ) logic. Detection of any fire should lead to auto shut off of the gas supply, total shutdown of the plant and blow down of the trapped gas to flare.

The fire water system should be capable enough to fight/control any fire situation within the installation effectively before the fire tender reaches at site from the nearby fire station.

9.1.1

COMPONENT OF FIRE WATER SYSTEM

Main component of fire water system is fire water storage, fire pump and distribution network. 9.1.2 BASIS

Fire water system should be designed in such a manner that at least one monitor of capacity approx. 1600 LPM or 2 nos. hydrant can operate in full pressure (7.0kg/cm2) in case of any emergency.

9.1.3

FIRE WATER STORAGE

At least 2 nos. welded tanks of capacity 40.0 KL each or one static ground reservoir of similar capacity should be made for water storage purpose at any EPS. Regular filling arrangement for the above mentioned tanks should be provided. Separate TPC connection should be provided in the welded tanks for fire tenders connection.

8.3.1

AREAS TO BE COVERED WITH DETECTORS

9.1.4

Fire Water Pump

The entire gas compressor area to be covered with hydrocarbon gas detector. The exact loocation and number of points shall be decided on need basis.

One trailer pump of capacity 1800 LPM at 7.0 kg/cm2 pressure should be installed and hooked up with the water storage facilities. 9.1.5 Fire Water Distribution Network

9.0

FIRE FIGHTING FACILITIES IN EARLY PRODUCTION SET UP (EPS)

In any early production set-up, the fire fighting facilities should be of following types: - Fire water system - First aid fire fighting equipment 12

Fire water line of 4 size should be made at two sides of the EPS along road side. Line should be at least 15.0 mtrs away from the hazardous area. This line should be hooked up with the delivery of the trailer fire pump. Provision should be made to pressurise the ringmain if required from the outside fire tender or any other reliable pressurised water supply.

9.1.6

Above ground piping

Piping network should be laid above the ground level. Height should be 300 to 400 mm from the ground and it should be supported at every 6.0 mtrs distance. It should be ensured that proper coating etc. to be provided on pipe near support. However, if required pipe can be laid below ground with proper protection arrangement as per OISD Standard 117.

area. Distance between the two hydrants or two monitors should not be more than 30.0 mtrs. Monitors should be installed in such a manner that it should be able to cover all the tanks as well as group unit area. Height of the hydrant valve should not be more than 1.2 mtrs. from the ground level.

9.2

First Aid Fire Fighting Equipment at EPS

Hydrant/Monitors Hydrants and monitors should be installed along the line to cover entire hazardous

Portable fire Extinguisher shou l d b e installed as per IS-2190. All fire Extinguisher should be kept under proper Extinguisher shed.

The minimum quantities of fire Extinguisher at various locations should be provided as per the followings: Area Separator/Group unit area Portable Fire Extinguisher 2 Nos. 10 kg DCP Extinguisher and 2 nos. sand bucket under one Extinguisher shed 1 No 10 kg DCP Extinguisher for each pump and with a minimum of 2 nos 10 kg DCP Extinguisher 1 No. 50 ltrs Mechanical foam Extinguisher and 2 nos sand bucket. 2 Nos 10 kg DCP Extinguisher 1 No. 6.8 kg CO2 Extinguisher 1 No. 10 kg DCP Extinguisher

i)

ii)

Dispatch pump area

iii) iv)

Near storage tank area Electrical switch gear area/Generator house

10.0

FIRE FIGHTING EQUIPMENT AT QUICK PRODUCTION SETUP (QPS)/Well Head Installation (WHI)

10.1

Fire water storage with fire pump

Quick Production Setup is a small production unit of temporary nature. Following minimum fire protection facilities should be installed: Fire water storage facilities with fire pump First Aid fire fighting equipment

One 40.0 KL capacity water storage tank should be provided at the approach area of the QPS. The tank should be of welded type with adequate thickness. One trailer pump of capacity 1800 LPM at 7.0 kg/cm2 pressure should be provided. The pump should be hooked up with the water storage tank. One additional TPC connection should be provided in the storage tank for connecting outside fire tender in case of emergency. Regular filling arrangement for the above mentioned tank should be provided.

10.2

First Aid Fire Fighting Equipment at QPS/WHI Area Separator/Group unit area Portable Extinguisher 2 Nos 10 kg DCP Extinguisher and 2 Nos sand bucket under an Extinguisher shed. 1 No. 10 kg DCP Extinguisher for each pump. Minimum 2 nos 10 kg DCP Extinguisher. 13

i)

ii)

Dispatch pump area

iii) iv)

Near tank storage area Generator house

2 Nos 10 kg DCP Extinguisher 1 No. 6.8 kg CO2 Extinguisher 1 No. 10 kg DCP Extinguisher

12.2

COMMUNICATION SYSTEM

11.0

MATERIAL SPECIFICATIONS
Adequate communication system like telephone/Public Address System/Paging System/ intrinsically safe Walkie-talkie system should be considered.

All the materials to be used in fire water system shall be of approved type i) Pipes: Carbon steel as per IS:3589/IS:1239 or its equivalent In case of saline water service the fire water main pipes shall be cu-ni, cement mortar/poly glass lined internally. ii) Isolation valves: Cast iron/cast steel. Use of cast steel valve is preferable iii) Hydrant Standpost : carbon steel Outlet valves: Stainless steel/Alluminium alloy Landing valves : Stainless steel/Al - Zn Alloy iv) Monitors :Carbon steel/Gun metal v) Fire hose : IS 636 : (Type A) or synthetic hose (Type B) Fire water network, hydrant, monitor etc shall be painted Fire Red.

13.0 FIRE SAFETY ORGANISATION/ TRAINING

13.1 (i) ORGANISATION Overall responsibility for fire safety in the oil installation shall be of the Location-in-charge. He shall draw the necessary emergency plan. Since separate fire fighting set up is not usually envisaged, one of the officers shall be designated and responsible for inspection of all fire fighting equipment. He shall also coordinate the activities during fire fighting. Hot work permit shall be issued by the Installation Manager.

12.0

FIRE ALARM AND COMMUNICATION SYSTEM FOR EPS/GCP/GCS FIRE ALARM SYSTEM

(ii)

12.1

(ii)

Electrical/hand operated fire siren shall be installed at suitable location in installation. The operating switch buttons shall be located near the Risk Area at a safe, identifiable and accessible location. The fire alarm shall be different from shift sirens. Fire siren code should be as follows: 1. SMALL FIRE: No siren

13.2

TRAINING

(i) The fire fighting training shall be compulsory to all officers, operators, and other employees who are likely to be present in the installation. There shall be regular mock fire drills, once a month. The record of such drills shall be maintained by the installation Manager. (ii) Every employee or authorised persons working in the oil installation should be familiarised with the fire alarm signal and should know the location of the fire alarm point nearest to his place of work. Instructions on the action to be taken in the event of fire should be posted at each alarm point and familiarity with these instructions should be ensured and recorded. (iii) OISD-STD-154 - Safety Aspects in Functional Training shall be adhered to in this regard.

2. MAJOR FIRE: A wailing siren for two minutes. Sirens will be sounded three times for thirty seconds with an interval of fifteen second in between. 3. DISASTER: Same type of siren as in case of Major Fire but the same will be sounded for three times at the interval of two minutes. 4. ALL CLEAR (For fire): Straight run siren for two minutes. 5. TEST: Straight run siren for two minutes.

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14.0

FIRE EMERGENCY MANUAL

Each installation shall prepare a detailed fire emergency manual containing all the actions to be taken in the event of fire emergency. The key points of this manual shall be displayed at strategic locations in the installation to ensure prompt action.

The ring mains, hydrants, valves should be visually inspected for any pilferage, effects and damage every month. All fire mains valves should be checked for operation and lubricated once a month. 15.3 FIRE WATER SPRAY SYSTEM

15.0

FIRE PROTECTION SYSTEM, INSPECTION AND TESTING

Fixed water cooling spray systems on storage tanks should be tested at least once a month. 15.4 FIXED/SEMI FIXED FOAM SYSTEM

The fire protection equipment should be kept in good operating conditions at all the time and the fire fighting system should be periodically tested for proper functioning and logged for record and corrective actions. Inspection of fire fighting equipment should be done in accordance with OISD-standard-142 on 'Inspection of Fire Fighting Equipment and System'. In addition to routine daily checks/maintenance, the following periodic inspection/testing shall be ensured.

Fixed/Semi fixed foam system on storage tanks should be tested once in 6 months. This shall include the testing of foam maker/chamber. The foam chamber should be designed suitably to facilitate of foam discharge outside the cone roof tank. After testing foam system, piping should be flushed with water.

15.1

FIRE WATER PUMPS 15.5 HOSES

Every pump should be tested for at least half an hour twice a week. Every pump should be checked and tested and the shut off pressure observed and logged once a month. Every pump should be checked for performance once in a six month. This may be done by opening required number of hydrants/monitors depending on the capacity of the pump and by verifying that the discharge pressure and the motor load are in conformity with the design parameters. 15.2 FIRE WATER RING MAINS

Fire hoses shall be tested once in 6 months to a minimum water pressure of 7 kg/cm2

15.6

COMMUNICATION SYSTEM Fire sirens should be tested once a week.

16.0

REFERENCES

The ring mains should be checked for leaks etc. once a year by operating one or more pumps with the hydrant points kept closed as required to get the maximum operating pressure.

OMR 1984 OISD-117 OISD-116 OISD-154 NFPA- 13,15,20 Fire Protection Manual (Part-II) of TAC

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