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PROJECT
CONCEPTUAL PROCESS DESIGN
OF
FIREWATER FACILITES
Client
Project
Refinery
FWI Contract N.: 1-BDRev.:
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TABLE OF CONTENTS
1.0
INTRODUCTION
2.0
OBJECTIVE
3.0
REFERENCE STANDARDS
4.0
FIREWATER DISTRIBUTION SYSTEM
4.1 Design Basis
4.2 System Description
4.2.1 Piping Layout
4.2.2 Hydrants Location and Spacing
4.2.3 Monitors Type and Location
5.0
FIRE SCENARIOS
6.0
DRAWINGS
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1.0
FWI Contract N.: 1-BDRev.:
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INTRODUCTION
The present document defines the conceptual design of the fixed firewater facilities for the
Project.
It includes information about the firewater piping distribution system and associated fixed
discharge devices such as hydrants, monitors and hose reels.
Fire scenarios are also included for the evaluation of firewater demand.
Firewater tank and pumps, firewater distribution to the area are outside the scope of this
conceptual design document.
Pag 1 of 13
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OBJECTIVE
This conceptual design provides the basic requirements and design criteria to be utilised for the
development of the detailed engineering design of fire fighting facilities for the Project area.
The scope of this package is limited to the conceptual design of the following fixed firefighting
facilities within the new grass roots area:




Fire water piping distribution
Hydrants location and spacing
Monitors location
Hose reels location
Mobile and portable fire-fighting facilities like hose nozzles, hoses, extinguishers, portable
firewater monitors, foam trucks, etc. are not covered by the present document and shall be
advised/provided by the Owner in accordance with local regulation and Refinery standards.
Model and type of fire-fighting equipment such as hydrant, valves and connections, fixed
monitors, portable monitors, dry chemical extinguishers, etc. shall be specified/confirmed by
the Owner.
Pag 2 of 13
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REFERENCE STANDARDS
Firewater system design is based on the following practices/standards:



The following drawing is taken as reference:

Pag 3 of 13
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FIRE WATER DISTRIBUTION SYSTEM
Firewater is supplied to the area by extending the existing firewater distribution headers to
provide a looped system.
The firewater headers will supply hydrants, firewater monitors and hose reels as well as mobile
and portable fire fighting equipment such as fire fighting equipment trucks, trailer mounted
monitors, hose nozzles, etc.
The following paragraphs provide the bases on which the firewater system has been developed
and a description of the firewater facilities
4.1
Design Basis
The fire protection facilities presented in this document are based on the assumption that only
one major fire might occur at any one time in the area.
Hence, the governing fire water rate for the Project has been determined by splitting the area in
subdivisions for which the maximum extent of any single fire has been established.
Each subdivision is separated from all others by a minimum of 15m clear space. Based on the
application of Project minimum equipment distances, the pipe rack is considered to ensure a
sufficient clear space to be regarded as a fire break between the north and the south side of the
unit, while the clear space (> 6 m) under the pipe rack itself is considered as a means of
firefighting access.
Fire water demand has been calculated based on the fire scenarios included under section 5.0.
Scenarios are based on the identification of the following equipment with a high fire potential:










(1)
(2)
(3)
(4)
(5)
P-502 A/B Feed Pumps (2)
P-504 A/B Product Pumps (2)
P-506 A/B Stripper Reflux/Distillate Pumps (1)
D-503 Hot Separator (4)
E-502 A/B/C Feed/Effluent Exchanger (4)
E-503 Hot separator Overheads/Treat Gas Exchanger
R-501 A/B Hydrofining Reactors (4,5)
C-501 Recycle Gas Compressor (3)
C-502 A/B Make-up Gas Compressor (3)
C-701 PSA Tail Gas Compressor (3)
Pumps with a rated capacity over 150 gpm (34 m3/h) handling light ends.
Pumps with a rated capacity over 200 gpm (45 m3/h) handling combustible
liquids when handled at temperatures above or within 15F (8C) of their closed
cup flash point.
Gas compressors over 200 hp (150 kW) handling flammable materials.
Vessels, heat exchangers and other equipment containing flammable liquids at
or above 600F (316C), or above their auto-ignition temperature, whichever is
less.
Reactors that operate at or above 500 psig (3450 kPa) pressure or are capable of
producing exothermic reactions.
Pag 4 of 13
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It is highlighted that as a deviation to the Project standards:
 EQUIPMENT STACKING, item 2.c;
 Table 1, ITEM E, point 3;
it has been foreseen, within structure “B”, the location of equipment in stacked position over
the following equipment containing flammable materials above 316°C or their autoignition
temperature:
 E-502 B/C Feed/Effluent Exchanger (below 316°C, above AIT)
 E-502 A Feed/Effluent Exchanger (above 316°C, above AIT)
 D-503 Hot Separator (below 316°C, above AIT)
 E-503 Hot separator Overheads/Treat Gas Exchanger (below 316°C, above AIT)
The following passive/active firefighting provisions have been foreseen in order to mitigate the
risk of a fire propagation in the structure:
 Fireproofing of structural steel;
 Solid deck between the levels in the structure fireproofed;
 Provision of fire monitors;
 Snuffing steam rings on shell girth flanges of E-502 A/B/C.
In addition to the above provisions, other features are included in the design to minimize any
risk of leaks (e.g. use of camprofile gaskets and Rotabolts on main exchanger flanges, manually
operated unit emergency depressuring facilities).
Fire fighting facilities (i.e. hydrants, monitors, hose reels) have been located and spaced in
accordance with Project standards
The possibility to reuse the existing hydrants (either relocated or in the same position) has been
taken into account in this document, as specifically indicated in the next paragraphs: the actual
position of the existing firefighting facilities shall be checked in field and the feasibility to
reuse them for the new installation (either relocated or in the same position) shall be confirmed
by the Refinery.
For a complete description of required facilities, reference can be made to paragraph 4.2
System Description.
4.2
System Description
The system description under this paragraph includes both existing and new or relocated
facilities.
The possibility of relocating existing firefighting facilities or accepting their present position
shall be evaluated and confirmed with the Refinery.
Hydrants and monitors location shall be reviewed and confirmed during detailed engineering
phase based on final equipment layout.
Reference is made to the FIRE FIGHTING SYSTEM drawing attached under section 6.0
Pag 5 of 13
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4.2.1 Piping Layout
Firewater is supplied to the process area by means of distribution piping tied from the existing
underground firewater headers.
The new fire water piping, except for branches to hose reels and to elevated monitors (if any)
shall be underground and buried 300 mm minimum below the frost line (0.6 m below grade).
Fire water connections to monitors, hose reels, etc. shall be designed to prevent water from
freezing in the connections and incorporate winterisation features by design.
Fire water main will follow the roadway layout.
Material of construction of the new firewater lines shall comply with Refinery specifications.
Two new 10” lines have been foreseen north and south sides of the unit in order to form a
closed loop around the area with the existing fire water line running east and west sides. The
loop is fed by multiple connections to the fire main.
An additional 8“ firewater branch, running underground along the unit pipe rack, has been
foreseen feeding the hose reels located inside the process area (see para. 4.2.4) and the two
monitors placed east side of the unit.
It has been considered to relocate the portion of the existing fire main running along the west
side of the unit to avoid interference with the new facilities and to allow placement of hydrants
and monitors at the opposite side of the road (18 straat) with respect to Project ISBL area.
Block valves have been located on the new headers, close to the tie-in points with the existing
fire main, so that not more than one side of the ring can be lost for maintenance or repair.
Piping and valves selection will be as per Refinery standard.
4.2.2 Hydrants Location and Spacing
Hydrants have been placed around the process area, located along the roadways, spaced not
more than 45m from each other. Fire hose boxes with hose, nozzles, branchpipes and couplings
will be installed near each hydrant or at strategic locations as per Refinery practice. Hose boxes
and their contents will be supplied and installed by Refinery.
The following hydrants have been considered for the protection of the unit; existing hydrants
have been also considered either in their original location or reused in a different position as
detailed in the following table:
Pag 6 of 13
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Hydrant N.
643
645
656
655
NEW
813
NEW
NEW
657
NEW
814
Location
East Side – Left corner
East Side – Right corner
East Side
North Side - Top corner
North Side
North Side – Lower corn
West Side – Left corner
West Side – Right corner
South Side– Top corner
South Side
South Side – Lower corner
Relocated
No
No
Yes
Yes
--Yes
----Yes
--Yes
Relocation of the existing hydrants shall be reviewed and approved by the Refinery.
Hydrants selection and installation will be as per Refinery standards.
4.2.3 Monitors Type & Location
Fixed water monitors have been located, at grade, in strategic position to protect critical
equipment and structures. Monitors are located approximately 15 m (50 ft) from the equipment
being protected; where closer spacing were required, the actuating valve shall be located at
least 15m from the protected equipment.
Monitors have been considered with an effective range of 45m (150 ft) under zero wind
conditions.
All monitors have been considered Style #649 Station Monitor (Protek) equipped with Style
#823 Master stream Nozzle (Protek) having a nominal capacity of 700 gpm (159 m3/h).
Monitor/nozzle selection shall be reviewed and approved by the Refinery.
Pag 7 of 13
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The following new monitors have been foreseen for the protection of the ISBL area:
Monitor
D5-1
Location
East Side
D5-2
East Side
D5-3
South Side
D5-4
South Side
D5-5
South Side
D5-6
West Side
D5-7
West Side
D5-8
North Side
D5-9
North Side
D5-10
East-west access way
Notes:
Covered Equipment/Structure
 PSA Unit X-701
 Feed Pumps P-502 A/B
 Product Pumps P-504 A/B (Note 1)
 Feed Pumps P-502 A/B
 Product Stripper T-503
 Structure “A”
 Structure “B”
 Reactors R-501 A/B
 Reactors R-501 A/B
 Treat Gas Furnace F-501
 Reactors R-501 A/B
 Treat Gas Furnace F-501
 Make-up Compressors C-502 A/B
 Make-up Compressors C-502 A/B
 Make-up Gas Compressors C-502 A/B
 Recycle Gas Compressor C-501
 PSA Tail Gas Compressor C-701
 Recycle Gas Compressor C-501
 PSA Tail Gas Compressor C-701
 PSA Unit X-701
 Recycle Gas Scrubber and KO Drum T-502/D-510
 Stripper Reflux/Distillate Pumps P-506A/B (Note 1)
 Recycle Gas Scrubber and KO Drum T-502/D-510
1) Due to the limited accessibility to pumps P-504 A/B and P-506 A/B, coverage by the
respective monitor shall be reviewed and confirmed at a later stage of plot plan
development. The possible adoption of fixed water spray systems shall be evaluated
and reviewed with Refinery.
4.2.4 Hose Reels
Hose reels (totally three) have been located within the process area, along the main pipe rack
with spacing at 60 m centres maximum, in order to cover the entire process area by means of
30 m length hoses.
Hose reels take water supply from a firewater header connected to two separate sections of the
fire main, with valves at each end where it connects to the main.
Pag 8 of 13
1
Client
Project
Refinery
5.0
FWI Contract N.: 1-BDRev.:
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FIRE SCENARIOS
The firewater demand for the ISBL area and fire protection systems presented in this document
are based on the following fire scenarios:
1.
2.
Fire in the Unit, south side of the piperack:
1.a Fire in Feed Pumps P-502 A/B area
1.b Fire in Structure “B”
1.c Fire in Reactors R-501 A/B Structure “C”
Fire in the Unit, north side of the piperack
The fire demand is based on the governing scenario.
Refinery shall confirm that the existing facilities (firewater pumps, distribution piping, sewer
pipes) are adequate for the below given firewater requirements.
Scenario 1.a: Fire in the Feed Pumps (P-502 A/B) area
In this scenario, fire is in the Feed Pump area, close to Product Stripper tower (T-503), Product
Pumps (P-504 A/B) and Structure “A”.
The new fire monitor (D5-2) installed at grade, east side of Feed Pumps, will be used to cool
the equipment on fire.
The new fire monitor (D5-3) installed at grade south side of Feed Pumps will be used to cool
Product Stripper tower (T-502) and equipment in Structure “A” area.
Additional three 2-1/2 in. hoses (from hydrants) are considered to provide additional surface
cooling and to control possible spill fires.
Extinguishing of the fire will be carried out with foam solution provided by Refinery fire truck.
Firefighting Devices
Water Demand
per device
m3/h (gpm)
159 (700)
57 (250)
Number of
firefighting
devices in use
2
3
Firewater
demand
m3/h (gpm)
318 (1400)
171 (750)
1
114 (500)
Water Monitors
Hoses (2-1/2 in.)
Foam solution by Refinery
114 (500)
Truck
Scenario 1.a - Total Firewater Flowrate
Pag 9 of 13
603 (2650)
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Scenario 1.b: Fire in Structure “B”
The present scenario considers the fire in the Structure “B”, at the location of Hot Separator
(D-503) and Feed/Effluent Exchanger (E-502 A/B).
The new fire monitor (D5-4) installed at grade south side of Structure “B” will be used to cool
the equipment on fire.
The new fire monitor (D5-3) installed at grade eastside of Feed Pumps will be used to cool
adjacent equipment in Structure “A”.
The new fire monitors (D5-5 and D5-6) installed at grade, respectively, south side and northwest side of Reactors structure will be used to cool Reactors (R-501 A/B) in Structure “C”.
Extinguishing of the fire will be carried out with foam solution provided by Refinery fire truck.
Additional three 2-1/2 in. hoses (from hydrants) are considered to provide additional surface
cooling and to control possible spill fires.
Firefighting Devices
Water Demand
per device
m3/h (gpm)
159 (700)
57 (250)
Number of
firefighting
devices in use
4
3
Firewater
demand
m3/h (gpm)
636 (2800)
171 (750)
1
114 (500)
Water Monitors
Hoses (2-1/2 in.)
Foam solution by Refinery
114 (500)
truck
Scenario 1.b - Total Firewater Flowrate
Pag 10 of 13
921 (4050)
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Scenario 1.c: Fire in Reactors Structure “C”
The present scenario considers the fire in the Reactors Structure “C”.
Due to the high operating pressure and temperatures above AIT a release in the form of a jetfire
can be expected.
It is noticed that both reactors are insulated and fireproofed.
The new fire monitors D5-4, D5-5, D5-6, located at grade adjacent to the Reactors structure,
can be used for cooling of reactor and of surrounding equipment directly impinged by the flame
or exposed to heat radiation.
Emergency depressurisation of the reaction section is foreseen, which can be activated in order
to deplete the leak source.
Firefighting Devices
Water Demand
per device
m3/h (gpm)
159 (700)
---
Number of
firefighting
devices in use
3
---
Firewater
demand
m3/h (gpm)
477 (2100)
---
---
---
Water Monitors
Hoses (2-1/2 in.)
Foam solution by Refinery
--truck
Scenario 1.c - Total Firewater Flowrate
477 (2100)
Scenario 2: Fire in the Unit, north side of the piperack
The process area located north side of the pipe rack is almost totally dedicated to equipment
processing flammable gases, lighter than air, at relatively low temperature (far below AIT),
like: Make-up Gas Compressors, Recycle Gas Compressor, PSA Tail Gas Compressor, PSA
Unit, Recycle Gas Scrubber, various K.O. drums.
Furthermore, it is noticed that each compressor is provided with emergency suction/discharge
isolation valves remotely actuable from control room, which allow a quick intervention for the
isolation of the possible source of gas leak.
Based on the above considerations, the event of a major fire in the area appears unlikely
provided that a quick response to a fire situation is initiated.
In order to avoid a potential fire escalation and prevent a prolonged unit downtime, fixed
monitors have been foreseen along unit perimeter in order to cover the following critical
equipment:
 Gas Compressors C-501, C-502 A/B, C-701;
 PSA Unit X-701 (including Adsorbers and Tail Gas Drum);
Monitors have been located in order to meet full coverage of the equipment from at least two
different directions (refer to monitors D5-6/7/8/9/1 location).
Pag 11 of 13
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Stripper Reflux/Distillate Pumps P-506 A/B, which handle a light ends product (wild naphtha)
above its flash point, is an additional equipment with a high fire potential located in this area: a
liquid spill might evolve into a vapour cloud that could explode if subject to a delayed ignition.
A dedicated monitor (D5-10) located at the east-west access way, at the top right corner of PSA
Unit, has been foreseen for the protection of pumps P-506 A/B.
Considering the absence of significant inventories of flammable liquids in this area and the
localized nature of a gas fire, the firewater demand in this area is considered to be not
controlling with respect to the fire scenarios identified for the process area placed on the south
side of the pipe rack.
Based on this consideration, it was deemed not necessary to develop specific fire scenarios in
this area.
Pag 12 of 13
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DRAWINGS
Drawing No.
Description
FIRE FIGHTING SYSTEM
Pag 13 of 13