FIRE PROTECTION SYSTEM FOR LARGE CHEMICAL STORAGE BY: MOHAMMED AL MUJAINI HSE MANAGER SALALAH METHANOL
Site Area
SALALAH METHANOL COMPANY
Construction Period: 3 Years
Man Power: 250
Area: 489,100 m2
Scale: A Day 3,000 TON Methanol
Location: Salalah, Sultanate Of Oman
Organisation: Salalah Methanol Company LLC (SFZ)
Process Technology: Low Pressure Methanol by Johnson & Matthey Catalyst Technology From Natural Gas to Methanol (Liq.)
Operation since 10 April 2010
Final Environmental Permit from MECA
Civil Defence Permit for Operating Plant
Ministry of Health
Permit from Salalah Free Zone
Chemical storage and Handling,
LEGAL QUIREMENTS
METHANOL
Hydroxymethane, Methyl alcohol Methyl hydrate, Wood alcohol wood naphtha, wood spirits Carbinol
CH3OH Often abbreviated MeOH
Physical Properties Clear, colorless liquid Made up of Carbon, Hydrogen and Oxygen
Important Properties (Flammable) Burns with at clear, low heat flame Biodegrades quickly, Soluble in water, Readily absorbed in the body.
1 3
0
Area : 489,100 m2
Storage Area
Methanol Process Area
Utility Area
Non Technical Building Area
Methanol
Storage Tank
54,000m3 x 2
Flare
W/H
LAB
Control Bldg
Admin Bldg
S/S
Storm Water Pond
Fire Water Pond
ETP Reformer Pkg.
SynGas Comp
Feed Gas Comp
N2 Plant
Air Comp
Power Gen S/S
Main S/S
STG Sea Water Cooler
Demi Water
Tanks
Desal Unit
Boiler
Flare Area
Electro Chlorination Unit
MeOH Converter
MeOH Distillation
Sec.
FTG
HSE Bldg.
SMC PLANT LAYOUT
DESIGN OF FIRE PROTECTION – APPLICABLE CODES AND STANDARDS
NFPA 11 Low expansion Foam
NFPA 13 Standard for the installation of Sprinkler systems
NFPA 14 Installation of Standpipe and Hose Systems
NFPA 15 Standard for Water Spray Fixed Systems for Fire Protection
NFPA 20 Installation of Stationary Pumps
NFPA 24 Standard for the Installation of Private Fire Service Mains
NFPA 25 Inspection, Testing & Maintenance of Water based Fire Protection
NFPA 72 Standard for Fire Alarm Code
BS 5274 Fire Hose Reels for Fixed Installations
BS 5306,Pt.1 Hydrant Systems, Hose Reels and Foam Inlets
BS 5423 Specification for Portable Fire Extinguishers
API 2004 Inspection for Fire Protection
API 2021 Guide for fighting fires in and around Petroleum Storage
API 2030 Guidelines for application of Water Spray systems for fire protection in the Petroleum industry
DESIGN CONSIDERATION OF FIRE PROTECTION SYSTEM
FIREWATER PUMPING CAPACITY AT SMC
Fire Water Pump Type
Nos. Capacity (Each)
(m3/hr)
Discharge Pressure
(Bar)
Fire water pump Elec. Motor 1 Sets 1144 10.5
Diesel Engine 2 Sets 1144 10.5
Jockey pump Elec. Motor 2 Sets 60.0 9.1
Sea water pump Elec. Motor 2 Sets 13,158 4.8
Only one major fire at any one time
Four hours of continuous fire fighting
Firewater from on site Firewater reservoir
9.1 bar Firewater network pressure
Mutual aid from Raysut Industrial Fire Services (Civil Defense)
EMERGENCY RESPONSE ORGANIZATION CHART
Notification by providing Information to Panel Operator on 23218999
Other Emergency Fire, Gas, Chemical Emergency Medical Emergency
Emergency Alert Telephone,, Plant Radio, PA System, MCP,
F & G Alarm, Person First on Scene
Alarm Confirmation by IC /designee
Communication to/from OOC and Shareholders
Information to/from Neighboring Plants, Regulatory & Vicinity
ERC CEO , Dy. CEO & Managers ECC
ECC Coordinator Head of Production / Shift Sup (Utility)
Decision Making
Incident Commander
All CLEAR
HSE Supervisor (1) Fire Chief (1)
Industrial Nurse (1)
Action to combat situation
ERT Members (29) EMT Members (08)
External Emergency Aid
EMERGENCY RESPONSE TRAINING
NFPA 1001: Fire Fighter Level -1 NFPA 472: HAZMAT responder Awareness Fire & Safety Engineering College (Muscat, Oman) •International Fire Services Accreditation Congress, USA (IFSAC) •National Fire Protection Association, USA (NFPA) •American Safety and Health Institute (ASHI), •Institute of Occupational Safety & Health (IOSH, UK) • Institute of Fire Engineers (UK).
Emergency Medical Team members MEDIC FIRST AID CarePlus CPR and AED Program.
In house refresher training programs are in progress at SMC by HSE department.
METHANOL STORAGE TANKS
Store Final product methanol (2X41000MT)
Max quantity that can be stored is 41000MT working capacity. Including dead vol it is 45000MT
Fixed roof tank with internal floating cover Impermeable bunds with 110% capacity. Large tanks with volatile products in single bunds. Good separation between tanks to prevent escalation. Independent level measurement with automatic shut- off of inlet valves on high risk tanks. Semi-fixed rim seal fire fighting systems for floating roof tanks.
FIRE RISK MANAGEMENT FOR METHANOL STORAGE TANK
SMC DESIGN RELIABILITY AND EFFICIENCY
Design and fabricated as per API 650 10TH& AWS
Design standard.
DOME roof tank
Internal Floating roof
All the welders and procedures are qualified as per
ASME section IX requirements.
Pre Service test
In service test as per API 653.
INTERNAL FLOATING ROOF
Each tank has internal floating roof.
Floating roof will move up and down according to liquid level.
Prevent vapor loss and generation
No oxygen contact
Designed to receive foam on rim seal.
NITROGEN BLANKET
Max Nitrogen blanket is at 520kg/hr per tank
The Nitrogen is used as sweep continuously in and out.
Prevents methanol vapor accumulation on the top of the tank and eliminates risk of fire
No air possible in the tank
Tank pressure control is automatic by Nitrogen blanket
BREATEHER VALVES
Each tank has 3 breathers
Work both ways +ve and –ve pressure.
During day time tank breathes out and night time breathes in
But due to nitrogen blanket, these valves only breath out nitrogen always don’t breathe in air.
In case of over-pressurization, they breathe out to air– for tank safety.
Manual Alarm Call Point 20
Warning Lamp 2 sets Motorized Siren / PA Speaker
FIRE & GAS ALARM, COMMUNICATION SYSTEM
RADIOS PROVIDED TO CONCERN PLANT EMPLOYEES AND
PA SYSTEM ALSO PROVIDED IN PLANT
UV/IR Detector 2 Gas & Smoke Detectors 6 D E T E C T I O N
W A R N I N G
C A L L P O I N T S I
FIRE SUPPRESSION SYSTEM
INSTALATIONS QUANTITY
Deluge Valve 8
Semi Fix Foam Pourer System 2
Water Monitors 12
Fire Hydrants 22
Potable DCP Extinguishers 16
Hose Cabinet (30 m length) – 100 ltrs foam. 8
5000 ltrs Mobile Foam Trolley 1
Fire Truck with 5000 ltrs Foam + 1000 Kg DCP. 1
Foam Generators 2
IMPACT DISTANCES FOR SCENARIOS (DNV)
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