Onshore Design Safety Philosophy

PARS OIL AND GAS COMPANY SOUTH PARS GAS FIELD DEVELOPMENT PHASE 1

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DOCUMENT TITLE

DAELIM IDRO

DOCUMENT NO.

Onshore Design Safety Philosophy

Proj. NO. SP1-100

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Apr. 10, 2001

Revised as per marked

B. S. Yoo

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Nov. 21, 2000

A.F.C

B. S. Yoo

J.R.Oh

Y.S.Kim

3

Sep. 08, 2000

A.F.C

B. S. Yoo

J.R.Oh

Y.S.Kim

2

Aug. 05, 2000

Issue for approval

B. S. Yoo

J.R.Oh

Y.S.Kim

1

Jun. 19, 2000

Issue for approval

B. S. Yoo

J.R.Oh

Y.S.Kim

0

Feb. 27, 2000

Issued for comment

B. S. Yoo

J.R.Oh

Y.S.Kim

Rev.

Date

Description

Prepared

Reviewed

Approved

Company


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DOCUMENT TITLE

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DOCUMENT NO. Proj. NO. SP1-100


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DOCUMENT TITLE Onshore Design Safety Philosophy

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Table of Contents PART AThe Onshore Facilities 1.

Introduction

1.1

General

1.2

Applicable Codes

2.

Project Safety Objectives

2.1

General

2.2

Design Criteria

2.3

Emergency Plans

3.

Location & Environmental Conditions

4.

Description of the Onshore Facilities

4.1

General

4.2

Refinery

4.3

Operating Base

4.4

Small Boat Harbour

4.5

Residential Camp

5.

Fire Water Network

6.

Communication and Alarm Systems

7.

Environmental Impact

7.1

Introduction

7.2

Gaseous Effluents

7.3

Liquid Effluents

8.

Noise and Vibration

8.1

General

8.2

Working Areas

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8.3

Vibration

9.

Safety of Equipment

9.1

General

9.2

Lifting Appliances

10.

Aviation Obstruction

PART B

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The Refinery

1.

Safety of Process and Utility Systems

1.1

Process Safety System

1.2

Relief and Depressurizing and Liquid Pulldown Systems

1.3

Flare Systems

1.4

Drainage and Spill Containment

2.

Hazardous Area Classification

2.1

Designation of Hazardous Area

2.2

Zone Definition

2.3

Battery Rooms

2.4

Selection of Explosion Protected Equipment

2.5

Safeguarding of Non-Hazardous Areas

3.

Personnel Safety

3.1

Introduction

3.2

Means of Exit

3.3

Safety Considerations

4.

Ventilation

4.1

Natural Ventilation of Plant

4.2

Requirements for Rooms

5.

Passive Fire Protection

5.1

Introduction

5.2

Structural Fire Protection

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6.

Active Fire Protection and Fire Fighting

6.1

Introduction

6.2

Fire Zone

6.3

Control of Fire Fighting Equipment

6.4

Fire Water Distribution

6.5

Fire Pump Control

6.6

Deluge Systems

6.7

Hydrants, Hose Reels and Monitors

6.8

Foam Systems

6.9

Carbon Dioxide System

6.10

Portable and Wheeled Fire Fighting Equipment

6.11

Steam Curtains

6.12

Steam Extinguishing & N2 inerting Systems

7.

Fire and Gas System

7.1

Objectives of the Fire and Gas Detection and Alarm System

7.2

Fire Detection Principles

7.3

Gas Detection Principles

7.4

Objectives of the Fire and Gas Executive System

8.

Emergency Shutdown System

9.

Emergency Signs and Alarms System

9.1

H2S Detection Alarm

9.2

Emergency and Safety Signs/Plans

10.

Emergency Power Supply

10.1

Introduction

10.2

General System Layout

10.3

Critical and Safety Consumers

10.4

Emergency Diesel Generators

10.5

Essential Switchboard

10.6

UPS-Systems

10.7

DC-Systems

10.8

Battery Rooms

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Emergency Lighting

10.10

Safety Lighting

11.

Fire Station

11.1

General

11.2

Mobile Fire Fighting Equipment

11.3

Foam Concentrate Storage

11.4

Various Equipment

11.5

Training Area

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Active Fire Protection System

2.

Fire Detection System Small Boat Harbor

1.

Active Fire Protection Systems

2.

Fire Detection Systems

3.

Navigation Aids

PART E 1.

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The Operating Base

1.

PART D

IDRO


10.9

PART C

DAELIM

Single Buoy Mooring (SBM) SBM Safety Requirements

PART F

Residential Camp (Deleted)

PART G

Telecommunication Buildings

1.

Introduction

2.

Active Fire Protection Systems

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Fire Detection Systems

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PART AThe Onshore Facilities 1.

Introduction

1.1

General This document considers the general design of safety and loss prevention systems and their interface with other disciplines for different parts of the Onshore South Pars Gas Field Development Phase 1 project including refinery, operating base, small boat harbor, sea water intake, condensate storage tanks and pipelines. For detailed description of other systems, reference should be made to relevant discipline documentation and other documents referenced in this Philosophy. The basis of the design shall be to make adequate provision, such that it can be demonstrated that; 

The installation is as safe as reasonably practicable and has a low probability of loss of human life or injury.



The risk of environmental pollution has been effectively minimized.



The capital investment is adequately protected.

Safety shall be of prime importance in the design of all systems associated with the South Pars Gas Field Development Phase 1 Onshore Refinery. 1.2

Applicable Codes The design shall be to the latest International Codes and Standards. These shall include but not be limited to the following; API RP 500

Recommended Practice for Classification of Areas for Electrical Installation at Drilling Rigs and Production Facilities on Land and on Marine Fixed and Mobile Platforms.

API RP 520

Design and Installation of Pressure Relieving Systems in Refineries

API RP 521

Guide for Pressure Relieving and Depressurizing Systems

IEC-79

Electrical Apparatus for Explosive Gas Atmospheres

NFPA

National Fire Protection Association Codes


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NFPA 10

Portable Fire Extinguishers

NFPA 11

Low Expansion Foam and Combined Agent Systems

NFPA 12

Carbon Dioxide Extinguishing Systems

NFPA 13

Installation of Sprinkler Systems

NFPA 14

Standpipe and Hose Systems

NFPA 15

Water Spray Fixed Systems

NFPA 20

Installation of Centrifugal Fire Pumps

NFPA 24

Private Fire Service Mains

NFPA 30

Flammable and Combustible Liquid Code

NFPA 54

Fuel Gas Code

NFPA 69

Explosion Prevention Systems

NFPA 72

National Fire Alarm Code

NFPA 86

Ovens and Furnaces

NFPA 101

Life Safety Code

NFPA 328

Gases in Manholes, Sewers

NFPA 655

Prevention of Sulphur Fires and Explosions

NFPA 1141

Fire Protection in Planned Building Groups

NFPA 2001

Clean Agent Fire Extinguishing Systems

BS 5839

Fire Detection and Alarm in Building, Code of Practice for Safety

Part 1

Design, Installation and Servicing

BS 5378

Safety Signs and Colors

Kuwait

Protocol Concerning Marine Pollution resulting from Exploration and

Protocol

Exploitation of the Continental Shelf.

EEMUA 107 Mechanical plant and Equipment Recommendations for Protection of Diesel Engines Operating in Hazardous Areas ICAO

International Civil Aviation Organization Recommendations

IP

Institute of Petroleum Model Code of Safe Practice in the petroleum Industry Part 2 Storage and Handling of Petroleum Part 3 Refinery Code Part 19 Fire Precautions at Petroleum and Bulk Storage Installations

The Mariner’s Handbook, British Admiralty, The Hydrographer of the Navy. Port Engineering, Per Bruin, Gulf publishing company.


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OSHA

Occupational Safety and Health Act

MCA

Manufacturing Chemists Association

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Sitting and Construction of New Control Houses for Chemical Manufacturing Plants

2.

Project Safety Objectives

2.1

General Within the limits of reasonable practicability the Project Safety Objectives are; 

To engineer a safe, reliable and operable facility at minimum cost through simple and effective design.



To ensure, throughout all stages of design, that the facility meets the latest international safety and environmental codes and standards, using the most cost effective measures available.

In achieving the above design objectives, the priorities shall be; 

Health and safety of personnel



Conservation of the environment



Protection of capital investment

The approach to achieving these subjects is the implementation of the following in order of preference.

2.1.1



Inherent safety/prevention



Control



Mitigation

Inherent Safety/Prevention The primary safety intent of the onshore facilities design shall be to ensure that any undesirable or hazardous events do not arise.

2.1.2

Control

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However, should they occur they should be promptly detected and acted upon automatically or manually (e.g. by the Fire and Gas System and Emergency Shutdown System) with the aim of reducing the risk to the operation personnel, surrounding civil population, the environment and minimizing the damage to equipment, plant and structures. 2.1.3

Mitigation The consequences of an accidental hazardous event may be in the form of thermal radiation, overpressure or release of toxic chemicals in liquid or gaseous form. The evaluation of the required safety measures shall be based upon the probability of an accidental event occurring and the extent of its consequential effects.

2.2

Design Criteria To priorities the aim of protection of personnel the onshore facilities design shall ensure that the following conditions are fulfilled; a) The use of high level design and construction standards as far as the safety aspect is considered. b) A minimal industrial risk associated with the complex under design. Internationally recognized codes and standards shall be complied with for the implementation of this goal. Where no specification exists to cover a particular aspect industry standards and normal good engineering practice shall be applied.

2.3

Emergency Plans The key to rapid response, should an emergency occur at the area is to have effective communication and procedures for alerting the personnel, controlling the effects and evacuation, if required. Such emergency considerations as alarms, availability of fire extinguishing systems and proper path of evacuation shall be incorporated into the design of onshore refinery.

2.3.1

Access


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Roads will be provided around all process units, product loading and tankage areas so that emergency equipment has access. Access should be assured to all refinery areas by roads wide enough to permit vehicles easy two way passage. Areas where tanker filling takes place should be fitted with appropriate barriers. Road transport demarcation should be taken into account when considering hazardous area classification. Because it may be necessary to block certain roads in emergencies, two or more approaches to each area shall be considered. Speed limits should be clearly indicated. Priorities should be marked at all road intersections. The relative location of main roads to process equipment should be considered because motor vehicles that use roads can be ignition sources. Turning radii should allow adequate space for mobile equipment to clear of pipe supports and equipment. Height warning bars and/or notices should be installed adjacent to elevated pipework crossings. Footpaths should be available for major roadways where large numbers of pedestrians are expected. Paths leading to storage tanks, pump bays and drainage systems should have weather resistant surfaces and be constructed so that they follow natural direct routes, thus eliminating the need for personnel to use improper and hazardous means of access. Ladders shall not be used in areas with a significant H2S risk (Such as the SRU area) as they could impede personnel using B.A. Only stairways shall be used in such areas. 2.3.2

Means of exit Clear passages shall be considered throughout the onshore facilities to enable personnel to evacuate the site quickly should an emergency occur. Adequate lighting shall be provided in the refinery. Where required by size, two exit ways shall be provided from elevated walkway, platforms and building. Specifically, all working areas, large rooms and corridors over 5m long in process areas will have two exit ways. All passages shall be clearly marked and sufficiently illuminated by safety lighting. For storage tank area, cement stairways shall be provided at suitable locations to have access to the outside of dike area. Doors in buildings shall have a minimum width of 0.95m and a minimum height of 2.05m. They shall open in direction of exit.


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Adequate audible warning shall be given to alert personnel of a site emergency. Every emergency exit door shall open outwards in the direction of escape and shall be equipped with a safe opening handle bar. Exit ways shall at all times be kept clear of equipment, materials, debris and any other obstacles which could impair safe evacuation. Emergency breathing apparatus shall be provided in areas where an emission of toxic gas may occur. The sets shall be air-purifying respirators type and shall have 10 minute duration to enable the wearer to reach a safe area. The specification shall be according to BS 2091. Operational procedures will need to be developed, for the allocation of breathing apparatus and training in its use. 2.3.3

Medical Facilities There shall be a clinic situated in the main administration block with an adjoining area which may double as an emergency incident room if required. The clinique shall be equipped as follows; 

Hospital type beds



Resuscitation equipment



Automatic electrocardiograph



Instrument sterilizes



Stretchers



1 No. WC, 1 No. Shower and 1 No. Vanity basin.



Portable defibrillator with monitor.



Refrigerator



Portable life saving system



Sink and worktop, Desk and chairs



Eyewash and Eyebath



Storage cabinets

The equipment to be confirmed in detail design.


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Location & Environmental Conditions The information provided by reference to; “Basic Engineering Design Data” - SP1-110-0000-00-PR-DB-101. “Environmental Conditions” - SP1-100-0000-00-PE-DB-102.

4.

Description of the Onshore Facilities

4.1

General The onshore facilities consist of four separate areas. These areas are; 

Refinery



Operating Base



Small Boat Harbor



Sea Water Intake

4.2

Refinery

4.2.1

General Layout Arrangement The general layout of the onshore facilities has been arranged taking into consideration the following points; 

Meteorological conditions



Safety



Accessibility during normal operation, maintenance and emergency



External access roads location



Topography

The refinery has been laid our to provide good access for fire fighting and good separation between process areas to enable equipment of one train to be maintained while the other train is running.


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The site is terraced with the non-industrial area located on a completely separate elevation from the industrial area. The industrial area is on its own elevation and is divided into process and utility areas with a large distance between them. The area between them is allocated to the control rooms and bulk chemical storage. The process and utility control rooms are located in a central position upwind of the process trains. They are separated from the high pressure area by the lower pressure condensate stabilization. The fire station has been located at the same elevation as the process areas but at the safe end of the terrace. The Condensate Storage Area is on the highest terrace together with the Sulphur Recovery/Handling areas. Each tank is surrounded by its own bund wall sized to contain the complete inventory of the tank. The separation distance of the bund walls from adjacent areas will ensure that a heat flux of 15 kW/m2 is not exceeded at the adjacent area in the event of a possible fire in the bund. Separation between storage tanks should be a minimum of 15 m. This is well exceeded due to the decision to individually bund each tank. The distance between the slug catcher and the adjacent process area was also checked against the same criterion of 15 kW/m2 at the process area in the event of a fire under the slug catcher. The distance was found to be adequate. Physical separation between process units and flaring equipment shall be considered according to code requirements. 4.2.2

Process Area

4.2.2.1

Basic Design Considerations The overall layout of the process areas shall be designed in order to incorporate the following;

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

Easy access for fire fighting.



Easy access for operators in order to perform emergency shutdown actions in a fire situation and minimize involvement of adjacent facilities.



Easy access for normal operation and maintenance.

In particular; 

Minimum separation between equipment of train 1 and train 2 which may be separately shutdown for extensive maintenance work shall be 30 m



Minimum distance of battery limit valves from equipment containing hydrocarbons shall be 7.5 m



Equipment containing large inventories of flammable materials shall be located on the outside of each process unit. Furnaces, being a potential source of ignition, where practical shall be located on the upwind side of each unit, on the outside of the unit area and at least 15 m from adjacent equipment which might provide a potential source of hydrocarbon.



High temperature pumps should not be installed beneath towers or drums. Pumps alleys should be sufficiently wide for access by mobile lifting equipments.



If large turbine/compressors are installed in enclosures, the buildings shall be fully ventilated open sided.



Permanent lifting equipment or access for mobile equipment, should be provided in all cases where heavy parts must be handled.



A minimum of two entry points should be provided into process units. Entry points should provide clear headrooms of at least 5 m and sufficient width to enable long vehicles to turn in from adjacent refinery roads.



Within process units, concrete roads and hard standing shall permit the passage of fire fighting appliances and cranes to all locations where they may be needed.



For pedestrian access, platforms and stairway. IP model code of safe practice Part 3 shall be applied.

4.2.2.2

Equipment Stacking A degree of equipment stacking is necessary to achieve a reasonable utilization of plot space, but the potential heavy fire involvement of equipment stacked in several layers must be avoided.


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The following restrictions shall apply. 

Stacking shall be limited, when possible, to no more than three levels of equipment.



Equipment handling liquid hydrocarbon shall not be located over any of the following. a) Compressors handling flammable materials b) Pumps handling liquid over its flash point c) Heat exchangers or drums containing flammable materials above 315C d) Piping possibly subject to vibrations such as;

4.2.3

-

Inlet/outlet lines of safety valves

-

Inlet/outlet lines of reciprocating compressors and compressors check valves

Buildings The below buildings in South Pars Gas Field Development Phase 1 shall have blast resistant structure against the potential vapor cloud explosion in accordance with category C of “MCA”; - Process control building - Utility control building - Laboratory building - Local equipment rooms (LER #1,2 &5) - Local compressor control room - Waste water control room - Substation No. 3 The structure shall withstand an explosion which generates an over pressure of 69 Kpa (10 psi) for 20 milliseconds (This value shall be confirmed after completion of fire and explosion study). Substation No.4, local control room(waste water) and local control room for metering and proving being located in areas with little or no explosion hazard shall be constructed in accordance with category A of “MCA” Substation No.2, main switch room & local equipment room No.4 shall be constructed in accordance with category B of “MCA” Other buildings such as toilet block, local technical room and local equipment room # 6 shall not have blast resistant structure.

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Condensate Storage Area The arrangement of tanks shall be planned with the aim of eliminating fire and explosion hazards to the greatest possible extent as explained in clause 4.2.1 of this section.

4.2.5

Condensate Export Condensate export facilities consist of condensate loading pumps, metering and proving package. 5km (approx.) transfer pipeline and a single Buoy Mooring (SBM) which is located in the sea, at a distance of about 1200m off the coast. Selecting the location of condensate export facilities shall be on the basis of isolating the area from other sections of the refinery because of probable hazard arising from large condensate inventory meanwhile keeping the required interfaces.

4.3

Operating Base

4.3.1

General Deleted

4.4

Small Boat Harbor

4.4.1

General Deleted

4.4.2

Sea Water Intake Deleted

4.4.3

Sulphur Storage And Handling Solid sulphur product shall be stored in sulphur storage building located in the harbor area.

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The transport of sulphur from storage to loading area shall be conveyed through conveyer belt placed in a confined corridor, to prevent wind blowing of sulphur. Fire and gas protection and detection for this area is discussed in Part “D”. 4.5

Residential Camp Deleted

5.

Fire Water Network Refinery, operating base and small boat harbor shall be protected by plant fire water networks, supplied by fire water storage tanks(6 hour capacity) via fire water pumps. Pumps at the Sea Water Intake(SWIP) will provide back-up supply of sea water if the storage tanks become depleted. Fire water demand shall be based on a single fire in a condensate storage tanks area.

6.

Communication and Alarm Systems The communication systems for the onshore facilities are covered in the onshore Telecommunication Philosophy SP1-100-0000-GE-TE-SP-112. Throughout the onshore facilities, alarm devices which are activated upon toxic and hydrocarbon combustible gas, fire, heat and smoke detection shall alert the personnel to initiate the countermeasures or start of an automatic shutdown.

7.

Environment Impact

7.1

Introduction The prevention of damages and the reduction of the impact on the environment shall be achieved through. 

Collection of the contaminated liquid effluents for disposal to proper treatment or to burning pit.

 7.2

Respect of international or local requirements in terms of air emissions.

Gaseous Effluents

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All flammable and/or toxic gaseous effluents shall be collected by closed piping systems and released to the atmosphere from incinerator or flare stacks. Release point to the atmosphere shall be at an elevation suitable to meet the local requirements in terms of air quality standards. Ground level concentrations for H2S and SO2 shall be in accordance with requirements of the relevant codes for a normal eight hour workday and short term exposure. For long term (8 hours) exposure, limits for SO2 and H2S are as follows;

7.3



SO2

2 PPM



H2S

10 PPM

Liquid Effluents Liquid discharged from the plant shall be grouped in the following categories; 

Liquid hydrocarbons release originated by emergency or upset conditions are collected into a closed blowdown piping system and disposed to a burning pit.



Liquid hydrocarbons release originated by minor drains or accidental spillage are led to API separators. Any resultant oil collected shall be recycled to the process.



Oily sour water is routed to a closed system and processed in a sour water stripper unit. The resultant sour gas effluent stream shall be sent to the flare system.



Processed seawater shall outfall through a pipe at the coast. Surface run off shall be directed, after oil separation, where appropriate to the flood protection channels which shall outfall at the beach. The relevant Kuwait Protocol conventions shall be observed in the oil content of water being sent to the sea.



Sanitary drainage is sent by dedicated server for treatment in the waste water treatment plant Liquid effluent from this plant is treated, Filtered and chlorinated to a sufficient standard for irrigation use on non-crop plants. The partially thickened sludge from this plant shall be transported by road tanker to the sewage treatment plant at the Residential Camp for further treatment.

8.

Noise and Vibration

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General Using the best practicable means of noise control, the following criteria shall be followed at any special location within a designated area to which personnel may have access, except for housing noisy equipment which are specifically designated as requiring ear defenders to be worn. The recommended criteria should generally apply at a minimum distance of 1 meter from operational equipment. In general, noise levels shall be limited throughout the installations to; a) Minimize the risk of hearing damage to personnel in work areas. b) Ensure that warning signals are audible. c) Allow adequate speech, telephone and radio communication. Whenever practicable noise control measures shall be carried out at source. All control valves on gas duty, and to lesser extent liquid duty, are significant sources of noise. The problem of noise shall be addressed by the use of low noise valves, especially on liquid lines which may be contaminated by sand. Where necessary, the associated pipework shall be acoustically insulated. The main power generators shall be supplied with acoustic enclosures and shall be fitted with in-duct silencers for the intakes and exhausts. Large compressors and pumps may need to be treated by using close acoustic cladding on the barrels and nozzles. Noisy gear boxes shall be fitted with acoustic hoods or close cladding. It is essential that quiet electric motors are purchased for all equipment. Examples of low noise control measures applied to electric motors are the use of low noise fans and or acoustic fan cover for TEFC motors. All process compressor suction and discharge pipework to and from the nearest large vessel (e.g. K.O drum or heat exchanger) and all recycle pipework shall be reviewed to determine the requirements for acoustic insulation.


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Vibration from rotating and reciprocating equipment should be kept to the lowest practical limits consistent with safe operation of the onshore refinery. 8.2

Working Areas The plant under consideration shall be divided into; a) General Working Area, to cover all work areas where personnel are exposed to the noise for not more than 8 hours per day. b) Restricted Area, to cover areas where personnel do not spend more that two hours. All working areas shall meet the general work area noise level limit of 90 dBA for an 8 hour working day. This limit is based on hearing damage risk considerations. These limits generally apply for broad band. Where a noise exhibits dominant tonal or implosive characteristics, then the required corrections shall be made. Where reliable speech, telephone or radio communication is required, or demanding mental tasks must be performed, then the noise limits for these areas shall be considerably less than the limit for general work areas. To determine permissible noise limits, modifications to basic limits for narrow band or impulsive noise and any relevant measures, applicable standards shall be incorporated.

8.3

Vibration All reasonable and practical means should be taken in the design of equipment and their installation to minimize the effects of vibration in the working areas to levels beyond which could cause a hazard to health, fatigue and decreased working efficiency.

9.

Safety of Equipment

9.1

General All the equipment necessary for carrying out any work on the refinery must be provided according to any written instructions specifying practices to be observed to ensure the safe use of that equipment.


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Lifting Appliances Every lifting appliance or piece of lifting gear, shall be plainly marked with its safe working load or loads and no lifting appliance or piece or lifting gear shall be used by a person for any load exceeding the safe working load thereon. Safety shut off devices shall be indicated in the design of all lifting appliances to limit the travel and prevent damage.

10.

Aviation Obstruction Aviation obstruction lights shall be installed on top of all structures with a height of 30 meters or more. The design criteria of the aircraft warning lights shall be in accordance with the recommendations of the International Civil Aviation Organization (ICAO).


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The Refinery

1.

Safety of Process and Utility Systems

1.1

Process Safety System The scope of the process safety system is; 

To prevent undesirable events that could develop into situation which could cause risk to personnel or equipment.



To shut down the process section where upset conditions are detected.



To prevent and escalation of upset conditions.

The process safety system shall provide two independent levels of protection against a single malfunction or fault in the process equipment and piping system including their controls. The two levels of protection shall in general be independent of and in addition to the control devices used in normal process operation and as a general rule provided by functionally different types of safety devices, in order to prevent common mode failures. Safety devices shall be of a fail safe nature. The primary level of defense will be the Emergency Shutdown System which shall be arranged such that the second level of defense (e.g. a pressure safety valve) is not activated as long as the first system properly operates. 1.2

Relief, Depressuing & Liquid Pulldown Systems The design philosophy shall be to; 

Provide on all pressure circuits two independent safety devices for protection from overpressure caused by a single process fault: the primary device shall be a switch or transmitter; the secondary device shall be a safety valve, a rupture disc or equivalent device.



HIPS(High Integrity Protection System) shall be selected, as an alternate of conventional system against over pressure, when full pressure rated designs and relief system prove impractical because of:


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The HIPS is based on instrumentation system which requires sufficient integrity (involving high reliability redundant instruments) so as to make the risk of exceeding the design pressure acceptable.



Provide all pressure systems that can be shut in during external fire with a PSV, to be designed for the worst overpressure condition, fire or process.



Equip all pressure systems, which can be isolated during an external fire with a manually actuated depressuring system in order to prevent fractures and loss of containment due to overheating of the equipment.



Liquid pulldown system shall be provided for the vessels containing more than 10 m 3 hydrocarbon liquid.



The high pressure systems shall be isolated into depressurisation zones.



Venting and relieving via specified line networks shall be done in such a way that no back pressure is produced.

All circuits treating hydrocarbons and other flammable or toxic fluids shall be conveyed through a piping system to closed systems connected to the flares. Depressuring valves and liquid pulldown shall be remotely operated from a location outside the area in which the equipment under emergency is located. For details refer to the Emergency Depressurisation Philosophy SP1-100-0000-00-PR-PH104. 1.3

Flare Systems Flaring is required to safely; 

Dispose of excess gas during start-up conditions.



Dispose of hydrocarbons from process equipment during relief conditions.

The flares of the onshore refinery shall comply with the following conditions. 

Radiation levels relative to personnel equipment and plant boundaries not exceeding 1.64 kW/m2 including solar radiation at a distance of 400 meters from flare and 4.73 kW/m2 including solar radiation at a distance of 120 meters from flare for continuous

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flaring and short duration emergency flaring respectively. 

Safe location with reference to air traffic.



Safe location with reference to flame-out conditions in terms of dispersion of the originated flammable/toxic vapor cloud.



Safe location with reference to entrained burning liquid droplets released from the stack.



Safe location with reference to a possible ignition by the flare of flammable gases accidentally released from the process units.



The high pressure flares shall be designed for continuous flaring during one train emergency shut down (see Overall Control Strategy). In case of prolonged shut down of the subject train, gas production from offshore shall be reduced accordingly.

All flares shall be equipped with a pilot flame system to ignite any released gas at any operating condition. A tip velocity of up to 0.4 Mach for the peak flow shall be considered in designing the LP & HP flare, with lower values expected for continuous operation. Purge gas shall be provided in order to sustain a stable flare flame and prevent potential flashback in the flare header at any operating condition. All flares shall be equipped with knock out facilities. Flare lines shall be sloped properly and equipped with silencers for noise reduction. For probable flashback suppression, a flare purge system shall be provided. 1.4

Drainage and Spill Containment The design of drainage and spill containment in hazardous areas shall be intended to accomplish the following objectives; 

To prevent the accumulation of flammable liquid under vessels or equipment.



To minimize as much as possible the chance of flame impingement on a vessel from a burning spill.



To provide a location for accumulating liquid that will minimize to the maximum extent the risk to critical facilities, piping and equipment if the pool ignites.



Safeguarding personnel from toxic gas propagation which shall be carried by drained


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fluids. Paving and adequate provisions for area under and surrounding the vessels shall be provided in order to direct any leaks or spills to a drainage system. Transit of spill from one process unit block to another shall be prevented, particular attention shall be paid to avoid back flow through the drainage system. Drainage facilities shall be arranged to handle specific categories of effluent. Liquid effluents released from pressurised vessels shall be discharged to burn pit via hard pipe drain lines(closed drain system). PVC shall not be used for this service. Due to the probability of toxic gas leaks from discharged effluents, self-contained breathing apparatus shall be provided at suitable points. Sufficient provisions shall be provided for the drainage of large quantities of water in case of fire fighting operations. 2.

Hazardous Area Classification

2.1

Designation of Hazardous Area All areas of the installation shall be either classified as hazardous or non hazardous. Classification of hazardous areas is based on API RP 500. Hazardous area classification drawings shall be provided based on process and piping arrangement drawings and the possible sources of release identified therein; 

Location of exhaust and relief vents shall be depicted in hazardous area drawings.



All air intakes for HVAC systems, turbine combustion, diesel engine and air compressor shall be positioned in non-hazardous area and kept at allowable distance from equipment exhausts and vents.

2.2

Zone Definition Hazardous areas shall be classified with the following zones; Class 1 Division 1:

Explosive gas air mixture is likely to occur during normal operation

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Explosive gas air mixture is less likely to occur and then only for short periods.

An area is designated as non-hazardous if an explosive gas air mixture is not expected to be present in such quantities that special precautions are required. 2.3

Battery Rooms Battery rooms need special consideration and have to meet related particular requirements. Electrical equipment installed inside shall be certified Ex-protected (i.e. suitable for installation in hazardous area) to meet the requirements of hydrogen generation if this is a possibility. Separate extract ventilation to maintain negative pressure against the surroundings shall be installed.

2.4

Selection of Explosion Protected Equipment Whenever possible, equipment which might from a source of ignition, should not be located in hazardous areas. Where this is impossible, equipment shall be selected so that it is suitable with regard to temperature class and gas group of the potential hazard. Special consideration shall be given to the surface temperatures of mechanical equipment. Electrical equipment for operation in hazardous areas shall be certified Ex-protected by a recognized international certification agency. Nevertheless it is anticipated, that all equipment which might form a source of ignition, even if located in a non-hazardous area, is shut down in case of a major or catastrophic hazardous event. Consequently equipment which is to be kept in operation for safety purposes under emergency conditions shall be suitably Ex-protected and certified. Other contractors shall consider their area equipment such as diesel fire pumps.

2.5

Safeguarding of Non-Hazardous Areas HVAC air intakes to control rooms and local technical rooms shall be located in non-


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hazardous areas on the prevailing wind side of any potential gas leak sources. The following areas shall be designed as non-hazardous areas, preferably by choice of location; 

Control and Technical Rooms



Offices and Stores

The extent of the hazardous areas shall be indicated on dedicated drawings. Area classification drawings shall include the following; 

All ventilation intakes and outlets



Intakes and exhausts of all fixed equipment



All external doors showing direction of opening



All drains and process vents

3.

Personnel Safety

3.1

Introduction This section covers the requirements for all measures to be taken to protect the personnel against possible hazards.

3.2

Means of Exit The requirement are discussed in clause 2.3.2 part A of this document.

3.3

Safety Considerations

3.3.1

Stairs and Ladders Stairs or steps shall be provided for height changes of more that 300 mm, with non-slip surface. For storage tank area, cement stairways shall be provided at suitable locations to have access to the outside of dike area. Fixed vertical ladders shall have a width of at least 450 mm and shall be equipped with safety cages.

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Continuous ladder height shall not exceed 9 meters without a landing. 3.3.2

Hazard Warning and Safety Signs Reference shall be made to BS5378 part 1, 2 and 3. Hazard and warning notices with reference to the admission of unauthorized persons and vehicles, naked lights, smoking, traffic hazards, speed limits, vehicular head room, toxic risk, etc. shall be prominently displayed. Also safety signs highlighting ear, eye and head protection, fire fighting equipment, fire and gas alarms, breathing apparatus, etc. shall be provided. Each main item of equipment shall be clearly identified, thus minimizing the risk of operational error. All signs should either be luminous or positioned near emergency lighting. Color coding of pipelines shall be used for emergency systems and lines carrying particular hazardous material such as H2S. Access roads shall be provided along the pipelines. High pressure vessels and equipments shall be installed at safe distances from the pipelines in accordance with the relevant codes. Luminous warning and signs indicating safe passage of vehicles along the pipeline shall be provided. Passing across the pipelines for operators and vehicles shall be via bridges installed at suitable distance. A clearly visible and unmistakable color marking system shall be used to facilitate rapid identification and location of equipment provided for emergency situations. Emergency exits from buildings and means of escape from other areas shall be clearly marked. Inside the internal corridors, potoluminescent arrows showing escape routes shall be installed at low levels, to assist escaping while too much smoke exists in the area. Text on all hazard warning and safety signs shall be in Farsi and English. Safety signs shall be provided throughout the refinery combining the geometrical shape, color and pictorial symbol to give specific health/safety or emergency information and or instructions for personnel. Text shall be in Farsi and English.


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Safety signs shall be in accordance with BS 5378. Emergency signs shall be provided to inform personnel of escape routes, emergency exits and fire-fighting equipment locations. All emergency signs shall be illuminated by one of the following means; 

Directly by the provision of emergency lighting.



Self-powered, luminescent



Photoluminescent

Rooms or enclosures protected with CO2 systems shall be equipped at their entrance with warning signs located outside the rooms to inform the personnel of possible CO2 discharge. 3.3.3

Safety Showers and Eye Baths In process areas where personnel might come into contact with hazardous and irritant material release, treadle safety showers with eye bath shall be provided. Each shower shall be supplied with cool and clean potable water, and the arrangement shall be such that a person standing on the operating platform shall receive overall saturation from multiple spraying head. Eye wash fountains with eyewash bottles shall be provided in battery rooms and laboratory.

3.3.4

First Aid Equipment First aid boxes shall be located at suitable locations throughout the refinery. Each first aid box shall contain, but not limited to, the followings; 

Eye wash bottle (eye bath),



Adhesive bandage (small & large),



Bandage compress (small & large),



Gause Bandage,



Adhesive tape,



Burn cream (tube),



P.V.P iodine swabs,



Eye dressing pads,



Wound wipes

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Thermal Insulation and Personnel Protection For the protection of personnel, all surfaces heated to temperatures above 70C, within 2.2 m vertically and 1.0 m horizontally of walkways or else where, which could be touched in the course of normal operating duties, shall be insulated or guarded. Surfaces in cold service that are at a temperature of -10C or below shall also be insulated or guarded.

3.3.6

Safety Notes in Sweetening, Sulphur Forming & Handling and Storage Area To protect the personnel against the toxicity in these specific areas, there shall be some procedures to be followed up; 

No visit to or walking in the H2S handling area,



Provision of a ready-to use self-contained respirator should be made available to any person that may be called to work in the H2S handling area (respirators should be fullscale tested),



Operators should never work alone in the H2S handling area,



Use of protective clothing, safety gloves, goggles in addition to the equipment usually worn in chemical plants,



A wind sock should be conspicuously placed to indicate wind direction.

As the hydrogen sulphide auto ignition temperature is relatively low and the explosive range relatively large, a number of precautions against fires should be taken and a separation area should be provided for around the facilities. Static electricity hazard should also be taken into account. The electrical equipment in the close vicinity of the plant should be of a nonsparking or sparkproof design. 4.

Ventilation

4.1

Natural Ventilation of Plant Process areas are to be kept as naturally and freely ventilated open areas, allowing the rapid dilution and dispersal of any gas leak and thereby minimizing areas where gas may

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accumulate and to vent explosion. 4.2

Requirements for Rooms Apart from providing conditioned air for personnel, it is necessary to protect the control and UPS systems and etc. against heat and humidity, regarding the environmental condition. The HVAC requirements for onshore facilities are covered in the onshore “HVAC DESIGN PHILOSOPHY”, SP1-100-0000-00-HV-PH-101. Minimum ventilation rates for some areas being potential sources of hazard shall be as follows; Room Type

Air Changes Per Hour

Laboratory

>5

Battery Room

10

UPS Room

2

HVAC air inlet and turbines combustion air, being taken from safe points, shall be so separated that cross contamination of ventilation air from other areas is prevented. 5.

Passive Fire Protection

5.1

Introduction Passive fire protection shall be such that to ensure that relevant structures or equipment and components have adequate fire resistance, with regard to load bearing properties, integrity and insulation properties and thus the consequences of fire are reduced as far as possible.

5.2

Structural Fire Protection In order to minimize the risk of escalating the hazard in the event of fire and to provide additional protection from the effects of support failure to fire fighting personnel, fire proofing material shall be applied to steel structures and supports for equipment and pipework containing flammable or toxic materials. The following supports and structures shall be fire proofed for a minimum period of 2 hours;


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

Piperacks in process areas and within 15 m of processing plant.



Structural steel supports and support skirts/saddles for vessels which can contain 5 tones or more of flammable hydrocarbon liquids or 15 tones or more of flammable hydrocarbon gas.

Passive fire proofing material shall be cement based. 6.

Active Fire Protection and Fire Fighting

6.1

Introduction The active fire protection equipment shall be employed for the prevention, control and extinguishing refinery potential fires. The active fire protection system consists of; 

Fire water and foam system



CO2 extinguishing system



Wheeled and portable extinguishers

Active fire protection systems and equipment shall be provided in all areas of the refinery that have a significant hydrocarbon inventory and or that are regularly manned. 6.2

Fire Zone All areas of the onshore refinery shall be subdivided into main fire zones and subzones as appropriate. Each fire zone shall be suitably equipped with proper detection and fire fighting systems. Calculation of the fire water, deluge quantities and other extinguishing capabilities shall be based on the definition of the fire zones. Means of fire fighting shall be designed and the capacities calculated on the basis of the defined designated fire zones and in accordance with the relevant NFPA codes.


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Control of Fire Fighting Equipment Control of the fixed fire fighting systems shall be automatic and/or manual as appropriate. Automatic and remote manual control will be via the Fire and Gas executive system For details refer to the relevant section of this document.

6.4

Fire Water Distribution

6.4.1

Capacity Fire water shall be distributed to every fire zone of the refinery except for enclosures containing electrical equipment (i.e. control room, instrument room, etc.) The capacity of fire water system shall be such that it supplies 6-hour fire water demand of the largest fire water zone to be protected. The maximum water consumption is based on a single fire in a condensate storage tank. The fire water demand for a tank on fire is based on cooling water required for fixed spray systems to cool the tank on fire and 50% of the surface area of two adjacent tanks (exposed to direct radiation), foam solution making and four hydrants plus a loss of 10%.

6.4.2

Configuration The firewater distribution system shall be designed as a ring main system. To protect the ring main against the risk of impact blast and resulting projectile, it shall be run underground. Supply from the ring main to each of the fire zones shall be through isolating valves. Closures of such a valve shall not inhibit the water supply to other fire zones. The ring main shall be provided with a sufficient number of isolating valves in order to isolate a damaged section of the main without causing isolation to other areas. All the isolating valves shall be installed in valve pits and kept normally open. In case of fire, the ring main shall be fed by two firewater storage tanks via 3  50% centrifugal type pumps (two electrical, one diesel driven) in accordance with the

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requirements of NFPA 20. The capacity of each pump shall be sufficient to meet 50% of the firewater demand of a single condensate storage tank on fire. The discharge pressure shall be high enough to maintain pressure of the ring main at 10 barg in case of a major fire. Pumps at the Sea Water Intake(SWIP) will provide back-up supply of sea water to fire water tanks if the storage tanks become depleted. The ring main shall be normally pressurized at 10 barg and the pressure drop below this level shall be compensated by Jockey pumps (one duty, one standby) with a capacity of 50 m3/h to avoid the main fire pumps starting too often and a differential pressure of 11.5 bar. In case of major release of water, upon low pressure of main ring detected by low pressure switch, fire pumps shall be started. Fire water tanks shall be supplied plant water through desalination package from sea water pumps (three electric driven pumps) located in the new sea water intake area. 6.5

Fire Pump Control Automatic start of the plant water fire pumps shall be done by automatic sequence starting under following conditions; 

Low pressure in the ring main



Command from the fire and gas executive system



Manual command from the local control panel/process control room

Pump stop shall only be initiated manually local to the pumps. The SWIP fire pumps(sea water) shall normally operate as manual start only. Though they will have the capability for starting on low fire main pressure. Pump stop shall be local manual. 6.6

Deluge Systems Uninsulated hydrocarbon vessels with capacity greater than 10m3, holding liquid volume of C4 and lighter products shall be equipped with a fixed water spray system. However vaporliquid separators upstream and downstream of propane chillers shall also be equipped with deluge facilities.

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The system shall be operated by means of deluge valves. Release of deluge shall be by activation from the Fire and Gas executive system or fusible plugs. In addition, local manual activation shall be possible. Closure of valves shall be locally only. Supply of fire water to deluge areas shall be from the fire ring main via isolation valves. The deluge valves shall be located outside the protected area to allow easy and safe operation. The status of deluge shall be signaled to Fire and Gas executive system. To cool the condensate storage tanks in case of fire, water spray nozzles shall be installed around the shell. In case of fire in one tank, spray system of the tank and those cooling half surfaces (half surfaces exposed to direct heat radiation) of the adjacent tanks shall be activated. The activation shall be manual and via push buttons installed in the process control room. 6.7

Hydrants, Hose Reels and Monitors Hydrants, Hose Reels and Monitors shall be fed from the ring main. Hydrants shall be located in process, storage and utility areas, hosereels in buildings. In process and utility area, hydrants shall be spaced at 45 meters apart and 60m for condensate storage area and common roads. Hydrants for common roads and condensate storage area shall have one additional 5-1/2" pumper connection. All hydrants shall be readily accessible. Each hose cabinet shall be equipped with three 20 m lengths of 21/2" dia hose, one 20m length of 11/2" dia hose, a hose nozzle. Hosereels in buildings shall be wall mounted (recess type). Fixed water monitors shall be provided in sulphur area to cover the equipment with cooling water in case of fire. They shall be capable of operating both manually and remotely from the


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process control room with a motorized isolating valve and water-powered automatic oscillating facilities. In Gas Treating train 1 & 2, Condensate Stabilization, Propane Storage area, and slug catcher, in which pool fire might exist, fixed foam/water monitors shall be installed. They shall be capable of operating both manually and remotely from the process control room with a motorized isolating valve and water-powered automatic oscillating facilities. The monitors shall be operated horizontally through a full 360 degree rotation and vertically in the range of –15 degree to +75 degree below and above horizontal positions. In process and utility area, portable monitors shall also be used for more flexibility viewpoint. Elevated fixed water monitors shall be used for protection of fin fan coolers. They shall be capable of operating both manually at ground level and remotely from the process control room with a motorized isolating valve and water-powered automatic oscillating facilities. 6.8

Foam System A foam system shall be provided for injection of AFFF solution at 3% (low expansion foam) into condensate storage tank rim seal area. A fixed foam pouring system shall be installed over the rim seal area of each storage tank which will automatically release foam on heat detection of electric wire. Foam concentrate shall be stored in two vessels. Each vessel will be arranged to serve two condensate storage tanks. Foam vessel capacity shall be sufficient for at least 30 minute continuous injection to one condensate storage tank.

6.9

Carbon Dioxide System Design shall be in accordance with the latest edition of NFPA-12. Fixed carbon dioxide fire extinguishing systems shall be provided in main switchroom, emergency generator rooms, electrical substations, local equipment rooms and gas turbine hoods.

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They shall be of the total flooding type. The extinguishing agent being CO 2 stored in pressurized bottles located in the vicinity. Automatic and remote manual actuation will be by the Fire and Gas System Manual local discharge shall be possible by direct actuation of the control. A predischarge alarm shall be provided locally and in the Central Control Room, 30 seconds before discharge commences. Protected areas shall be arranged and designed such that ventilation is stopped and fire dampers are closed automatically prior to discharge of CO2. To ensure the safety of personnel entering a CO2 protected area, the CO2 system should be mechanically locked out before entering the room. Interlocking the electrical releases with the door is not adequate, and the manual-mechanical local release is still available. The mechanical lock-out must physically prevent CO2 from being released into the room, if the rooms are entered by personnel. Automatic and manual remote release (e.g. operator manual release from Process Control Room) shall be inhibited on the F&G panel when the manual isolation is selected. The CO2 system status shall be displayed in the Process Control Room (PCR) including the discharge inhibit state. Manned rooms do not require a fixed fire fighting system. Location of the nozzles about the machinery shall be arranged to ensure a uniform concentration of CO2 in all parts. An adequate amount of CO2 shall be provided for flooding equipment and UPS rooms under protection to concentration of not less than 50% within 7 minutes as deep seated fire in accordance to NFPA 12. 100 percent preconnected reserve cylinders shall be supplied and an automatic switch over system between main and reserve cylinders shall be considered. Appropriate CO2 warning signs shall be displayed at all entrances to areas protected by carbon dioxide. For turbine protection will be with turbine supplier.

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Portable and Wheeled Fire Fighting Equipment Portable and wheeled fire extinguishers shall be provided at strategic locations around the refinery. The following types of portable fire extinguishers shall be used as appropriate to the type of risk. 

For areas where there are ordinary combustibles, such as wood, cloth, paper, plastic, etc. extinguishers shall be suitable for Class A fires. These can be water, foam or dry powder.



For areas where there are flammable liquids, oils, greases, paints etc. extinguishers shall be suitable for Class B fires. These can be dry powder, carbon dioxide or foam.



For areas where this are energized electrical equipment extinguishers shall be suitable for Class C fires. These can be dry powder or preferably carbon dioxide.

These shall be portable or wheeled dependent on the size of extinguisher required. Fire extinguishers shall be located as follows; 

Buildings and stores - 9 litre water.



Process, utility and condensate storage 12kg dry powder, and 45kg wheeled dry chemical (Plus 9.0 lit. foam for condensate storage).



Laboratory, 6kg CO2, 12kg dry powder, 9 litre water.



Process & utility control rooms, 6kg CO2,, 12kg dry powder



Local control rooms 6kg CO2, 12kg dry powder



Local equipment rooms and battery rooms 6kg CO2 5

Portable extinguishers located in exposed areas shall be mounted in weatherproof cabinets. 6.11

Steam Curtains Furnaces and heaters nearby flammable gas handling facilities, such as those in Gas Treating train 1 & 2, shall be equipped with steam curtains to dilute the explosive gases arising from the vessels. Upon high concentration of flammable gas detection in these areas, the steam curtain shall be activated. To prevent burning hazard to the personnel working in the area, the activation shall be manual.

5


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6.12

Steam Extinguishing & N2 Inerting Systems

6.12.1

Fires in tanks containing large inventories of liquid sulphur can be fought with saturated

5

steam. Hence, in Sulphur Recovery plant, the liquid sulphur storage tanks shall be equipped with flushing steam lines to extinguish any fires which may occur. Steam extinguishing system shall be in accordance with NFPA 86 & 69 and activated manually. 6.12.2

N2 inert gas in sulphur silo(1-V-65001/1-V-65002) shall be provided for fire fighting using by emergency on/off valves on nitrogen supply header.

7.

Fire and Gas System

7.1

Objectives of the Fire and Gas Detection and Alarm System The Fire and Gas Detection system shall be provided to perform, but not be limited to, the following duties; 

To monitor all designated areas for fire;



To monitor all areas where flammable materials might be present in the course of normal operations;



To monitor all air intakes together with airlocks located in zone 2 area for concentration of toxic gases;



To monitor air intakes for concentration of flammable gases;



To provide a facility for raising a fire alarm;

To alert personnel in the process control room, utility control room and fire station of any fire or gas emergency situation;

7.2



To activate the automatic fire fighting system and the ESD System



To alert personnel in the Central Control Room of any fault detected by self test facilities;

Fire Detection Principles

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All loops and detectors of the system shall be arranged in such manner that any arising hazard can be easily located. No loop shall cover more that one fire zone. The fire and gas cause and effect charts shall detail the alarm and executive actions taken on operation of smoke, heat or flame detectors or manual controls for each zone in the refinery. Except the line detectors over the rim seal area of the condensate storage tanks, detection in two loops shall be required in order to initiate an executive action. Detection in one loop shall alarm only. However smoke detection in rooms shall stop HVAC and close fire dampers only. 7.2.1

Manual Alarm Call Points (MAC) Manual alarm call points, as break glass push buttons, shall be provided at strategic locations adjacent to exit from and along the peripheries of process areas. According to NFPA Code they shall be located so that no person has to travel more than 60 m to reach a MAC. In condensate storage and slug catcher area, the distance between MACs shall be further. A MAC shall only initiate an alarm and not start the fire pumps. In building, MACs shall be located on exit routes and in particular on the stairways and exits to the open air. They shall be so located that, to give the alarm, no person in the premises need travel more than 30 meters. MACs shall be connected in a single loop by fire zone.

7.2.2

Smoke Detectors (SD) It is assumed that smoking will be permitted in offices and public rooms. Ionization or optical smoke detectors shall be provided to monitor the following enclosed areas; 

Offices



Public areas and corridors



Control rooms



Local equipment and technical rooms



Battery, and HVAC plant rooms



Void spaces, false ceilings and false floors


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Smoke detectors shall be connected on two loops where executive action (e.g. process shutdown is required. Where they activate alarms only they shall be connected on a single loop. Where they shut down the ventilation to an affected area only, they shall also be connected on a single loop. 7.2.3

Heat Detectors

7.2.3.1

Electric Heat Detectors (HD) Heat detectors, which operate at a pre-determined fixed temperature shall be installed in enclosed areas where local conditions are not considered suitable for smoke detectors, e.g. due to high humidity. Rate of rise heat detectors shall be used in laboratory and mess hall.

7.2.3.2

Electric Line Heat Detectors (DELH) Electric line heat detectors shall be installed above rim seal area of each condensate storage tank. Electric line heat detectors sensing shall initiate release of foam.

7.2.3.3

Fusible Plugs (FP) Fusible plugs shall be installed in process areas which are protected by deluge systems. Melting of the plugs shall vent pneumatic pilot lines and directly activate deluge release from the pressurized fire ring main. Release shall be alarmed via a pressure switch to the Fire and Gas executive system for further processing. Fusible plugs shall be located as close as practicable to the equipment they protect without impeding maintenance.

7.2.4

Flame Detectors (IR) Optical detectors responding to infrared characteristics shall be installed in process areas where there are large inventories of hydrocarbon. They shall not be used in engine rooms

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due to the possibility of black body radiation. They shall, as a minimum, be installed in pairs, at separate locations to monitor an area Detectors in each fire zone shall be connected on two loops. The operation of a single detector will initiate an alarm two will give a confirmed fire condition for extinguishing release and further executive action and start the fire pumps. Flame detector positions will be based upon each particular area and shall take account of the obstructions caused by equipment and services. Care shall be taken during equipment selection and arrangement that solar and other radiation sources (e.g. flare/burn pit) do not cause spurious operation. 7.3

Gas Detection Principles

7.3.1

Combustible Gas Detection Sensors for combustible gas detection shall be located in process areas and HVAC inlets where the accumulation of gas and/or the release of gas can be expected. Portable gas detectors shall also be provided. Preference shall be given to the use of infra-red as opposed to catalytic gas detectors. Infra-red open path detectors (Line of sight detectors) are recommended as an alternative to point detectors in open area. Point detectors shall be used in HVAC intakes and under gas compressor sunshades and around vessels and equipment handling gases heavier than air and located at lower points. Line of sight detectors shall be considered around the perimeter of train 1 and 2 of Gas treating units and condensate stabilization & fuel gas to give early warning of gas cloud moving toward operating base. In process areas the detectors shall be located in such a manner that a majority voting 2 out of N can be reasonably performed in order to activate the ESD system, avoiding spurious alarms and further actions due to single detector malfunctioning. Air intakes shall be equipped with at least two sensors to enable majority voting. Two alarm levels shall be provided. For point detectors the first level shall be at 25% of the Lower Explosive Limit (LEL), giving an alarm and the second at 60% LEL, causing executive


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action. For open path detectors the first level shall be at 0.5 LEL m*, giving an alarm and the second at 1.2 LEL m, causing executive action. Provision shall be made for applying a test gas from a remote point to the gas detectors. * LEL m = average % lower explosive limit × portion of beam occupied in meters. 7.3.2

Toxic Gas Detection The hydrogen sulphide detectors shall be provided in the area which equipment contains

5

H2S toxic gases in the process area of 5,6 and 7. The hydrogen sulphide detectors shall be direct installation type without need of a sampling system. They shall be protected using permeable stainless steel sintered disc and shall be poison resistant. Sensor replacement shall be easily made by using a permanent base and plug-in type connector. The hydrogen sulphide sensors will be connected to electronic modules that shall be capable of displaying gas concentration in PPM and generate alarms at desired set points. The range of sensors shall be 0-50 PPM. Toxic gas detectors shall employ electro chemical cell detection technology with 4~20 mA signal transmission. Two independent alarms with the set point adjustable from 0 to 100% of range, shall be provided. No majority voting shall be performed on toxic gas detection but a toxic gas alarm shall be immediately issued and HVAC systems shall be stopped if toxic gas is detected in the air intakes. Two alarm levels shall be provided at 5 PPM and 10 PPM of H2S. In sulphur handling and storage area, toxic(SO2) detector shall be provided for indicating any flame on solid sulphur and the detail information shall be shown on the related documents such as gas detector location plan, gas detector data sheet and safety

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application chart. 7.4

Objectives of the Fire and Gas Executive System The fire and Gas executive system shall be provided to perform the following duties; 

To evaluate the signals from the fire and gas detection system, using voting techniques where necessary.



To activate visual and audible alarms.



To automatically activate appropriate fire fighting system in emergencies.



To activate fire fighting systems on manual initiation from an operator control panel in the PCR/UCR.



To provide a manual start facility for the fire pumps.



To signal the ESD system for further automatic action.



To activate fire and gas damper closure via the HVAC system as appropriate



To stop the HVAC system as appropriate



To monitor state and availability of the fire fighting systems



To Indicate any action taken on a panel in the CCR



To log all F & G actions.

All field cables of the F & G System shall be fire resistant. 8.

Emergency Shutdown System The onshore facilities shall be provided with an Emergency Shutdown System (ESD) to ensure the safe isolation and shutdown of equipment under hazardous upset of fire/gas conditions and provide depressuring possibility. There shall be four levels of shutdown Level 1

Refinery Shutdown (Process Plant and/or utility Shutdown, manual)

Level 2

Train / System Shutdown (Process Units Shutdown, automatic or manual)

Level 3

Single Train Shutdown (Process Unit Shutdown, automatic or manual)

Level 4

Equipment Item Shutdown (Manual or Automatic)

For details refer to the Emergency Shut-down Philosophy SP1-100-0000-00-PR-PH-103.

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Emergency Signs and Alarms System Emergency alarm devices shall be provided to alert personnel to an alarm condition. Emergency alarm systems may be divided into two main parts the active system (audible and visual alarm) and the passive system (organization and procedures). In addition, an audible and visual alarm shall be provided for the following purposes; 

Carbon dioxide status lamps



Carbon dioxide pre-discharge sounder alarm

The audible alarms will be rated at least 5 dB(A) above the maximum ambient noise level. In buildings, fire alarms shall be intermittent bell type and for evacuation, continuous bells shall be used. For areas other than buildings, the following alarms shall be utilized; 

Wailing sirens for fire & gas



Continuous sirens for evacuation

In areas of high ambient noise levels, the alarms shall be supplemented by visual indications i.e. red rotating beacons for confirmed flame and combustible gas detection. 9.1

H2S Detection Alarm H2S detectors monitoring buildings air intakes shall initiate audible and visual alarms in the process control room, fire station and affected area(s) and HVAC systems shall be stopped. The visual alarm shall be yellow colored.

10.

Emergency Power Supply

10.1

Introduction An emergency power supply system shall be provided for all consumers, which are to be operational under emergency conditions. Consumers which are needed during periods where the main power supply is not available (e.g. startup) shall be connected to this supply. The emergency power supply system shall consist of two diesel generators, connected to a


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dedicated part of the low voltage switchboard (hereafter called the emergency). 10.2

General System Layout The emergency power supply systems shall be located in a safe area, separate from the main power generation and protected from external fires. Hence, one of the generators shall be installed beside the substation no. 1 and the second one adjacent to substation no. 2. All cabling of the system that is required to operate under emergency conditions shall be fire resistant. In general all electrical consumers shall be graded in three categories; N

:

Normal

E

:

Emergency

S

:

Safety (Essential)

Emergency and essential consumers shall be supplied with electrical energy under emergency conditions from the generator, if no break supply is required by certain consumers this shall be via UPS-systems. Shut down and load shedding of consumers fed from the emergency switchboard under emergency conditions shall be considered when main power fails. 10.3

Emergency and Essential Consumers The following systems shall be supplied from the emergency diesel generator for a duration of at least 24 hours. a) Directly 

Emergency Lighting

b) Via AC UPS-System 

Process Control System



ESD System



Fire and Gas Detection



Fire Fighting Electrical Equipment

c) Via DC UPS-System


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Public Address System



Radio Equipment

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Electrical control and protection

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In case of failure of the diesel generator the essential systems which are supplied with battery backup either through AC or DC UPS-Systems will be kept alive until the battery capacity is exhausted after 4 hours. 10.4

Emergency Diesel Generators The emergency power shall be generated by two diesel generators connected to dedicated emergency panels. The diesel day tanks shall have sufficient capacity to enable each diesel generator to run at full load for at least 24 hours. The diesel generators shall be started automatically if the main power supply falls. After return of the main power supply, switch over to the latter shall be initiated manually and by means of synchronizing thus avoiding a blackout on the emergency switchboard.

10.5

Emergency Switchboard The emergency switchboard shall be located near the low voltage switchboard and shall be equipped with all control and protection devices for the emergency consumers and the emergency generator. Under normal operation conditions it shall be fed from the main power supply system via bus tie circuit breaker. Synchronizing of the emergency generator with the main power supply system shall be possible. If consumers are supplied form the emergency switchboard, which are not safety consumers but needed under special conditions, when the main power is not available (e.g. startup) load shedding shall be considered for emergency operations.

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UPS-Systems In addition to the emergency generations, additional sources of power by means of static UPS-Systems shall be provided for consumers which need an uninterruptible power supply. The UPS-Systems shall consist as a minimum of; 

Rectifier



Battery bank



Inverter



Static bypass switch



Manual bypass switch



Bypass transformers

The capacity of the battery bank shall be sufficient to supply the connected loads for an autonomy period as mentioned in item 10.3. The UPS-System shall be fed from the emergency switchboard. 10.7

DC-Systems Where consumers require a DC-supply, this shall be provided by dedicated DC-System with battery back-up for an autonomy period of four hours. The system shall be equipped with two rectifiers, each with sufficient capacity to provide for the full load current to the consumers and additionally the full charging current for the batteries. The rectifiers shall be fed from the emergency switchboard.

10.8

Battery Rooms Batteries shall be located in dedicated rooms, separate from their chargers. The rooms shall be equipped with separate exhaust ventilation systems. Interlocks shall be provided between the ventilator and the rectifiers in order to inhibit boost

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charging of the batteries if the ventilation is out of operation. Electrical installation in battery rooms shall be Ex-protected and certified for use in hydrogen atmosphere, gas group IIC temperature class TI. 10.9

Emergency Lighting Emergency lighting shall be provided for the illumination of control rooms, technical rooms and other areas of the onshore refinery, which are critical for operation. The emergency lighting system shall be supplied from the emergency switchboard. In each area the emergency lighting shall be made so that the area is illuminated via two separate circuits. On of these can be a main lighting circuit. Failure of one circuit shall not render an area completely dark. The emergency lighting fixtures shall be Ex-protected, in accordance with hazardous area classification.

10.10

Safety Lighting The safety lighting system shall illuminate all emergency routes and exit points from buildings and other areas which are critical to the operation and emergency conditions. The safety lighting shall be fed from the emergency switchboard. Safety lighting shall be provided by use of luminaries with a battery back-up system and integrated battery charger having an autonomy period of 90 minutes after failure of the emergency power supply. The safety lighting fixtures shall be Ex-protected, even if installed in safe areas.

11.

Fire Station

11.1

General


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A fire station shall be built at a safe location (in southwest part of the sub sleeper way area) and constructed with noncombustible materials.



A work bench shall be included in the inventory of this station. Facilities for inspecting, cleaning and filling fire-fighting equipment shall be provided.



Electric power, apart from the usual lighting, shall be provided to charge the batteries of the fire-fighting truck via a rectifier.



A fire attendant console shall be installed and facilities for personnel, such as restroom, furniture, etc., shall be provided.



A mimic panel shall be installed in the fire station to monitor fire & gas hazard in onshore facilities (except residential camp) by receiving common alarms from affected areas.

11.2

Mobile Fire-Fighting Equipment At least the following mobile fire-fighting equipment shall be provided in the fire station of the refinery plant; 

Water/foam trucks, 2 Nos.



Dry powder truck, 1 No.



Foam concentrate trailer, 2 Nos.



Service vehicle, 1 No, (Landrover or equivalent) with a suitable quantity of flexible hoses, branch pipes and dry powder extinguishers.

11.3



Ambulance, 1 No, air conditioned, complete of first aid equipment, for two persons.



Twin agent vehicle, 1 No.

Foam Concentrate Storage An elevated, on structure, foam concentrate storage tank shall be provided for quick filling by gravity of water/foam trucks.

11.4

Various Equipment An adequate quantity of fire brigade equipment shall be provided. The equipment considered shall be; 

Portable CO2 extinguishers, 10 Nos.



Wheeled CO2 extinguishers, 5 Nos.



Fire hoses, 10 Nos.


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Hose jackets, 10 Nos.



Fire shield, 5 Nos.



Water branchpipes, 15 Nos.



Foam branchpipes, 15 Nos.



Fire rescue suits, 5 Nos.



Proximity suits, 5 Nos.



Helmets, 20 Nos.



Fire blankets, 5 Nos.



Breathing apparatus, 10 Nos.



Gas masks, 30 Nos.

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Training Area For training of fire purpose, a fire brigade exercise area shall be provided at east side of the fire station. Also, a training ground shall be provided for practical fire trainings. The ground shall be near the fire station to the possible extent and shall not impose hazards to the other parts of the onshore facilities. Hence, northwest of the off-plot, outside of the flare sterile area shall be considered. The requirement for training area shall be defined during detail design.


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The Operating Base

Active Fire Protection System Active fire protection equipment shall be employed for the prevention, control and extinguishing of fire in different parts of operating base. The active fire protection system in this area consists; 

Fire water system



Wheeled and portable extinguishers

The operating base shall be divided into fire zones and subzones. Each subzone shall be properly equipped with suitable detection and fire fighting systems. The operating base and H/C drain and waste water treatment area shall have an independent fire water ring which shall be supplied by the sea fire water pumps located in the sea water intake area. There are links with check valves between this ring and the refinery ring main which can supply fire water to the operating base and waste water treatment area, if required. The ring main sizing shall be on the basis of three hydrants in simultaneous operation. For preventing the probable damages to the ring, it shall be run underground. Chemical storage area shall be protected by water sprinkler system which shall be automatically activated by heat detection. Administration, warehouses, fuel filling station areas are protected by water hydrants spaced at a distance of 60 m accompanied by hose boxes wherever required, hose reel in buildings, warehouses and workshop. For more flexibility, beside each building a hydrant shall be installed. The specifications are similar to those specified for the refinery. In all buildings 8kg portable dry powder extinguishers shall be located except the substation which is protected by 6kg portable CO2 extinguishers which are located inside and outside of the building. Substation shall also be protected by CO2 flooding system activated by confirmed fire detection. For fuel filling station protection, 45kg wheeled type dry powder and 9-litre portable foam


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extinguisher shall be considered. Workshop building shall also be equipped with 9-litre portable water extinguisher. In canteen No. 1, No. 2 and bakery fire blanket suitable for being utilized by personnel shall be located. 2.

Fire Detection System Administration offices, general warehouse, auditorium and substation shall be equipped with smoke detectors. In general warehouse area, smoke detection shall be done by photoelectric detectors operating on light obscuration principles. They are beam type, respond to the smoke generated by low energy fires and are used to protect large open areas. Canteens & Chemical storage shall be equipped with rate of rise heat detectors. Manual alarm call points (MACS) shall be installed at the exits and inside of the building. Those located inside of the buildings shall be spaced at 30 meters apart. Activation of each one of them shall initiate an alarm in the affected building. There shall be an alarm in the general area of the operating base to be manually activated from the fire station by the personnel in charge. Signals from the detection systems shall be sent to a mimic panel in fire station to indicate the exact point of fire in the operating base area. And also a signal shall be sent to the PCU/UCR providing a common alarm to alert the personnel of refinery of a fire condition in the operating base area.


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Small Boat Harbor Active Fire Protection System Small boat harbor shall be divided into fire zones and subzones. Each subzone shall be properly equipped with suitable detection and fire fighting systems. The area shall have a fire water ring which is linked to main fire water pumps or sea fire water pumps located in the sea water intake area. The ring main sizing shall be on the basis of three hydrants in simultaneous operation. For preventing the probable damages to the ring, it shall be run underground. Sulphur storage shall be protected by water spray system to be activated manually in case of fire. Drainage of the fire water contaminated by sulphur after spray system activation to a proper route in order not to pollute the sea water shall be connected to the industrial sewage basin.

2.

Fire Detection Systems Sulphur, on burning, gives off a little amount of heat and the fire so produced will not emit significant amounts of infra red radiation in the sensitive range of the IR detectors. Hence, Ultra Violet (UV) flame detectors shall be considered to monitor any fire in sulphur storage. In the meantime, the design for reducing sulphur cast concentration in the area will progress on the basis of consideration, of natural ventilation and incorporating mechanical system to provide adequate back-up. Signals sent from the detection systems shall follow the same principle as in the operating base and also shall be received in small boat harbor area.

3.

Navigation Aids

3.1

Harbor and Approaches To provide the vessels to stay within limits of maneuvering area both in harbor and approach channel, the limits of these areas shall be marked with seamarks.

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The seamarks shall provide; 

Visual identification of the harbor general location from distance.



Demarcation of the harbor approach channel

Radio communication with the vessels shall be provided in the harbor. The following general safety rules shall be followed in entrance and/or departure of the vessels and shall be considered as the minimum basis for the design of mooring facilities; 

The vessels speed approaching the harbor shall not exceed 10 knots at entrance channel.



Berthing shall be avoided when wind velocity exceeds 8 m/sec, visibility is less than 1 nautical mile and wave height exceeds 1.2m.



Berthing speed shall be limited to 10 cm/sec.



All berthing structures shall be provided with fendering system in such distances to absorb the shock of vessels during berthing. The fenders shall extend down to low water level. Fenders shall prevent any direct impact and contact of vessel to the berthing structure and to be capable of absorbing and damping vibrations.

Also, in harbor area two maritime obstruction lights (beacon lights) shall be installed with a range of visibility of not less than 5 nautical miles. Operation of the light shall be monitored automatically and automatic transfer to a standby circuit shall be initiated in case of light failure. The color of the lights shall be white the lights shall be Ex-protected. The maritime obstruction lights shall be supplied from the essential switchboard with a battery back-up to give an autonomy of at least 96 hours. The lights shall flash to give a Morse letter “U” every 15 seconds in accordance with International Association of Lighthouse Authorities (IALA) recommendations. Two foghorn shall be also provided in the harbor area with a minimum range of 2 nautical miles. The foghorns shall be supplied from the essential switchboard with a battery back-up to give an autonomy of at least 96 hours.

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The foghorns shall be Ex-protected. The foghorns shall sound the Morse “U” every 30 seconds in accordance with IALA recommendations. The unit shall be fitted with sufficient emitters so as to provide adequate safety should one fail. The fog warning signal supply circuit shall incorporate a control switch mounted on the battery box/control panel to temporarily silence the signal in the event of personnel working around the unit when there is clear visibility. Signs (warning plate) shall be provided near the foghorns to warn personnel of high sound pressure levels in the vicinity. Navaid Radio System and Meteorological monitoring packages shall be provided to support marine, helicopter and aircraft operations.

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Single Buoy Mooring (SBM) SBM Safety Requirements For exporting produced condensate, a Single Buoy Mooring (SBM) shall be located in the sea, at a distance of approximately 1200 m from small boat harbor. SBM is normally unmanned. To provide visual identification of the SBM general location from distance at night time and fog condition, maritime obstruction lights with a range of visibility of not less than 5 nautical miles, foghorns with a minimum range of 2 nautical and radar reflector shall be installed on SBM. The equipment shall be ex-protected and supplied by batteries. Obstruction lights and foghorns provided at SBM shall follow the same regulations and specifications defined in section 3.0 of part D (NAVIGATION AIDS).

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Residential Camp Deleted

PART G 1.

Telecommunication Buildings Introduction Telecommunication system is composed of two microwave multi-junction and three microwave terminal stations. Multi-junction stations and Vali Asr Refinery terminal stations are normally unmanned. Terminal station building at operating base includes some offices. Thus it is considered to be manned. Residential camp terminal station is unmanned but is located at manned area. Active fire protection and detection devices shall be considered for telecommunication system on the above-mentioned basis.

2.

Active Fire Protection Systems All telecommunication buildings shall be equipped with 8kg portable dry powder and 6kg portable CO2 extinguishers. Hosereels shall be installed in corridors (in areas that fire water ring exists). In fire condition, the extinguishing equipment installed at unmanned buildings shall be used by the personnel present in guard houses located in the vicinity. They shall be trained for such cases.

3.

Fire Detection Systems Air sampling type smoke detectors shall be considered for rooms in which equipment are located while for offices and battery rooms, ionization type smoke detectors shall be installed. Utilization of air sampling type smoke detectors instead of ionization type for offices and battery rooms shall be reviewed during detail design.

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Fire detection signals in Junction and Vali Asr terminals shall be received in adjacent guard houses. The fire signals in terminal located at residential camp shall be received in fire station. Fire detection signal in operating base terminal station shall be connected to a general alarm inside the building and also received at fire station. Manual alarm call points shall be installed at manned buildings according to the principles mentioned earlier in this document.

Onshore Design Safety Philosophy

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