EP FF 02 PH Philosophy Passive Fire Fighting

Philosophy for Passive Fire Protection Systems

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July, 02 2007

Rev. No.

Date

Issued for Comment/Approval

Description

D.N. Pantazi

N. Jugravu

M. Doloszeski

Prepared

Checked

Approved

Originator

Document Title: Philosophy for Passive Fire Protection Systems

Rev: A1

Document Number: EP FF 02 PH

Engineering & Maintenance Department

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Authors

4 3 2

Nicolae Jugravu

1

Daniel Nicolae Pantazi

No.

Engineering & Projects Division Surface Engineering & Maintenance Dept. Engineering & Projects Division Surface Engineering & Maintenance Dept. DIVISION Department

Name

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Rev: A1

Document Number: EP FF 02 PH

Engineering & Maintenance Department

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Philosophy for Passive Fire Protection Systems July, 02 2007

TABLE OF CONTENTS 1.

PREFACE ......................................................................................................................... 4

2.

DEFINITIONS .................................................................................................................. 4

3.

ABBREVIATIONS ............................................................................................................ 5

4.

INTRODUCTION ............................................................................................................. 5

5.

APPLICABLE CODES, STANDARDS AND REGULATIONS.......................................... 5

5.1

Codes and Standards List.............................................................................................. 6

5.2

References..................................................................................................................... 12

6.

SYSTEM GOAL ............................................................................................................. 12

7.

SYSTEM BOUNDARIES................................................................................................ 13

8.

DESIGN PHILOSOPHY ................................................................................................. 13

8.1

Risk Analysis ................................................................................................................. 14

8.2

Design Criteria .............................................................................................................. 15

8.3

Types of Available PFP Systems ................................................................................. 16

9.

DESIGN CONSIDERATIONS ........................................................................................ 17

10.

MAINTENANCE IN DESIGN......................................................................................... 17

11.

DOCUMENTATION REQUIREMENTS......................................................................... 17

12.

CERTIFYING AUTHORITY REVIEW REQUIREMENTS ............................................... 18

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1. PREFACE This Philosophy defines the Petrom E&P corporate policy on the design of Passive Fire Protection (PFP) Systems for onshore hydrocarbon production and processing facilities. The document specifies basic requirements and criteria, defines the appropriate codes and standards, and assists in the standardization of facilities design across all onshore operations. The document was elaborate by adaptation of TO-HQ-02-073 Rev 00 Philosophy for Passive Fire Protection Systems - Onshore in respect to Romanian Regulations. Implementing the Philosophy will be made with respect for Romanian valid Laws, Orders, Normative and Regulations, as mentioned below. The enumeration is not exhaustive and limitative. The design process needs to consider project specific factors such as the location, production composition, production rates and pressures, the process selected and the size of the plant. This philosophy aims to address a wide range of the above variables, however it is recognized that not all circumstances can be covered. In situations where project specific considerations may justify deviation from this philosophy, a document supporting the request for deviation shall be submitted to Petrom E&P for approval. 2. DEFINITIONS The following definitions are relevant to this document. Cellulosic Fire

The combustion of cellulosic fuels, such as: wood, paper, textiles, certain plastics, etc.

Fire Rating

Time during which a structure or component will provide prescribed resistance to transmission of heat, passage of flame, smoke and toxic gases and structural failure.

Fire Area

An area that is physically separated from other areas by space, barriers, walls or other means in order to contain fire within that area.

Hydrocarbon Fire

The combustion of hydrocarbon fuels.

Hydrocarbon Jet Fire

The ignition and subsequent combustion of a pressurised hydrocarbon leak.

Intumescence

A physical and chemical change, which results in the expansion of the PFP material by several times its applied volume forming a char of low thermal conductivity, which absorbs heat.

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Muster Area

Designated area where personnel report when required.

Pool Fire

Combustion of flammable liquid spilled and retained on a surface.

Sublimation

The direct change of a PFP material from solid to vapour effectively absorbing heat to execute the phase change.

3. ABBREVIATIONS The following abbreviations are relevant to this document. PFP

Passive Fire Protection

BLEVE

Boiling Liquid Expanding Vapour Explosion

ESDV’s

Emergency Shut Down Valves

FERA

Fire and Explosion Risk Assessment

EERA

Escape, Evacuation and Rescue Analysis

IGSU

General Inspectorate for Emergency Situation

4. INTRODUCTION This document defines the Petrom E&P corporate policy for the design basis and philosophy of Passive Fire Protection (PFP) on its onshore facilities. By specifying the basic requirements and criteria, and defining the appropriate codes and standards, this philosophy intends to guide the selection and design of PFP Systems and standardise this process across all onshore facilities operated by Petrom E&P. 5. APPLICABLE CODES, STANDARDS AND REGULATIONS Codes, standards and regulations referred to in this philosophy shall be of the latest edition and shall be applied in the following order of precedence: 1. Local Regulations and valid Standards mentioned in these 2. European Directive Rev:

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3. National Directive 4. National harmonized with European Standard 5. European Standard and Codes 6. International Standard and Codes The applicable norms and standards of the organizations listed below shall be considered as part of these criteria. All documents shall be the latest editions in force on the date of issuance of this document. Whenever a difference exists between this document and any referenced publications, the more stringent requirements shall govern. 5.1

Codes and Standards List

I Laws, Government Decisions, Orders 1

Law nr. 307 din 12.07.2006

Related to the defence against fires

2

Order nr. 163 from 28.02.2007

For the approval of General Norms related to the defence against fires

3

Order nr. 130 from 25.01.2007

For the approval of the Methodology of issuing the fire safety scenarios

4

Order nr. 132 from 25.01.2007

For the approval of the Methodology of issuing the Analysis and Risk Plan and the General Structure of the Analysis and Risk Plan

5

H.G.R. nr. 1739 from 06.12.2006

For the approval of construction categories and establishments which are submitted to the fire safety approval/authorization

6

Order nr. 108 from 01.08.2001

For the approval of General Provisions regarding the decrease in fire risks generated by electrostatic trials D.G.P.S.I.-004

7

Order nr. 47/1203/509 from 21.07.2003

For the approval of the Procedure for issuing of the construction permit for the establishments placed in the vicinity of the objectives/systems belonging to the oil and gas industry

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Order nr. 1435 from 18.09.2006

For the approval of the Methodological Norms for the authorization regarding fire safety and civil protection.

9

HG 1058/2006

Related to the minimum requirements for the improvement of the safety and security of the workers exposed to potential risks in explosive atmospheres.

Directive 99/92/CE from 16.10.1999 10

Order nr. 87 from 14.06.2001

For to the approval of the Methodology related to the identification, evaluation and control of fire risks

II Specifications, Norms, Codes, Regulations 1

Normative NP 08605

Related to the design, manufacture and use of fire fighting equipment

2

Normative P 118-99

Fire safety of the buildings

III STAS, SR 1

STAS 10903/2-79

Fire protection. Determination of fire load in buildings. Produse petroliere si lubrifianti. Sistem de clasificare. Definirea claselor de produse.

2

STAS ISO 8681-92

3

SR 3317:2003

Natural gas. Quality requirements

4

SR 4163 series standard

Water supplies. Distribution networks.

5

SR CEI 60839 series standard

Alarm systems

6

SR ISO 6241:1998

Performance standards in building. Principles for their preparation and factors to be considered

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(Oil and lubricant products. Classification systems. Class products definitions)

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SR ISO 7162:1998

Performance standards in building. Contents and format of standards for evaluation of performance

8

STAS 6647-88

Safety measures in case of fire. Fireproof elements for the protection of walls’ and roofs’ holes. General technical specifications

9

STAS 185/1

Sanitary installations for central heating, ventilation and natural gas supply. Pipes for fluids. Conventional identification items and colors.

10

STAS 6793-86

Cosuri si canale de fum pentru focare obisnuite la constructii civile. Presciptii generale. (Stove pipes, flues for civil buildings. General prescriptions) Cosuri si canale de fum pentru instalatii de încalzire centrala. Prescriptii de calcul termotehnic.

11

STAS 3417-85

(Stove pipes, flues for central heating installations. Calorific calculus prescriptions) Instalatii sanitare. Alimentarea cu apa la constructii civile si industraiale. Prescriptii fundamentale de proiectare.

12

STAS 1478/90

13

SR 12294:1993

(Sanitary installations. Water supply for civil and industrial buildings. Engineering general prescriptions) Artificial lighting industrial security lighting

IV SR ISO, IEC, EN Harmonized Romanian Standards 1

SR EN 12416 series standard

Fixed fire fighting systems - Powder systems

2

SR EN 13501 series standard

Fire classification of construction products and building elements

SR EN 1634 series standard

Fire resistance tests for door and shutter assemblies

3

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SR EN 60598-2 series standard

Luminaries

5

SR EN 2/1995

Classification of fires

6

SR EN 1127-1:2003

Explosion prevention and protection. Part 1: Basic concepts and methodology

7

SR EN 13237:2004

Potentially explosive atmospheres - Terms and definitions for equipment and protective systems intended for use in potentially explosive atmospheres

8

SR EN 26184 – series standard

Explosion protection systems (ISO 6184)

9

SR ISO 8421 – series standard

Fire protection. Vocabulary.

10

SR ISO 6309:1998

Fire protection. Safety signs

11

SR EN ISO 13943:2002

Fire safety. Vocabulary

12

SR ISO 6790:1998

Equipment for fire protection and fire fighting. Graphical symbols for fire protection plans. Specification

13

SR EN 2:1995

Classification of fires

14

SR EN ISO 13702:2001

Petroleum and natural gas industries - Control and migration of fires and explosions on offshore production installations Requirements and guidelines (ISO 13702:1999)

15

SR EN 61508

Functional Safety of Electrical/ Electronic/ Programmable Electronic Safety Related Systems

16

SR EN 54 series standard

Fire detection and fire alarm systems

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SR EN 60079 series standard

Electrical Apparatus for Explosive Atmospheres

18

SR EN 60529

Ingress Protection Code

19

SR EN 61511

Functional safety - Safety instrumented systems for the process industry sector

20

SR EN 61131 series standard

Programmable controllers

21

SR EN ISO 9001:2001

Quality management systems. Requirements

V Standards outside EU 1

API-RP14C

Recommended practice for analysis, design, installation and testing of basic surface safety systems for offshore production platforms

2

ISA-RP 12.13.02

Recommended Practice for the Installation, Operation, and Maintenance of Combustible Gas Detection Instruments

3

ASTM E 119

Standard Test Methods for Fire Tests of Building Construction and Materials

4

ASTM E 515

Effect of Overheating Steel

5

ASTM D 635

Burning Rate and Burning Time after Ignition for Basic Epoxy Resin

6

ASTM E 760

Standard Test Method for Effect of Impact on Bonding of Sprayed Fire-Resistive Material applied to Structural Members

7

BS 5839

Fire Detection and Alarm Systems for Buildings

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BS 476

Fire Tests on Building Material for Design and Installation

9

BS 3900

Test Methods for Impact Effects on PFP

10

BS Part 20

BS Fire tests on building materials and structures. Method for determination of the fire resistance of elements of construction (general principles)

11

BS Part 21

BS Fire tests on building materials and structures. Methods for determination of the fire resistance of load-bearing elements of construction

12

BS Part 22

BS Fire tests on building materials and structures. Methods for determination of the fire resistance of non-load-bearing elements of construction

13

BS Part 23

BS Fire tests on building materials and structures. Methods for determination of the contribution of components to the fire resistance of a structure

14

ISO R 834

Fire-resistance tests - Elements of building construction

15

NFPA 33

Standard for Spray Application using Flammable and Combustible Materials

16

NFPA 59

Standard for the Storage and handling of Liquefied Petroleum Gases at Utility Gas Plants. Appendix D: Procedure for Torch Fire and Hose Stream Testing of Thermal Insulating Systems for LP Gas Containers

17

NFPA 251

Standard Methods of Tests of Fire Endurance of Building Construction and Materials

18

NFPA 703

Fire Retarding Coatings

19

UL 263

Standard for Fire Tests of Building Construction and Materials

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UL 1709

5.2

References

Standard for Rapid Rise Fire Tests of Protection Materials for Structural Steel

IP Guidelines for the Design and Protection of Pressure Systems to Withstand Severe Fires, (March 2003) IP Model Code of Safe Practice, Part 19 - Fire Precautions at Petroleum Refineries and Bulk Storage Installations Guidelines for Fire Protection in Chemical, Petrochemical and Hydrocarbon Processing Facilities, AIChemE Publication (2003) Handbook of Fire and Explosion Protection Engineering Principles for Oil, Gas, Chemical and Related Facilities, Dennis, P. and Nolan, P.E., Noyes Publications (1996) EP FF 01 PH

Philosophy for Fire and Gas Detection Systems Onshore

TO-HQ-02-071

Philosophy for HSEQ Management Onshore

EP FF 03 PH

Philosophy for Active Fire Fighting

TO-HQ-02-075

Philosophy for Escape, Evacuation and Rescue Onshore

6. SYSTEM GOAL The goal of the PFP Systems shall primarily be for the protection of personnel in the event of a fire or explosion with secondary consideration being given to the protection of plant and equipment combined with environmental protection requirements. The PFP Systems shall achieve their goal by: •

Protecting personnel on the installation against Hydrocarbon Fire and jet fire

• Preventing and/or containing explosions or delaying the event of BLEVE on pressure vessels • Preventing the escalation of fires due to progressive release of inventory, by separating designated Fire Areas Rev:

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• Protecting safety systems for sufficient time to enable them to carry out their intended function •

Protecting safety critical components such as vessels, spheres, tanks, ESDV’s, etc.

• Minimising the likelihood of the collapse of tall structures and equipment that can potentially cause escalation and/or impair Muster Areas/shelters and escape facilities. • Protecting critical structural members and those associated members essential to maintain the integrity of designated Muster Areas and essential shelters • Protecting any section of escape routes to designated safe areas for a predetermined time to allow safe escape from the area and to enable essential emergency response activities to be carried out. • PFP may also be considered for the protection of equipment whose failure in case of a local fire could cause extensive damage to the environment and assets. Note: This philosophy does not consider the Fire Rating requirements for ‘Remote’ inhabited buildings. 7. SYSTEM BOUNDARIES The boundaries of the PFP Systems are with the following: •

extent of designated Fire Areas and the plants physical boundaries

•

interface with primary/secondary safety critical structures

•

interface with physical structural barriers; walls, decks, etc

•

interface to safety critical equipment and associated supports

8. DESIGN PHILOSOPHY It is not intended that this philosophy be used retrospectively. It should be applied to new facilities and to major modifications and/or extensions to existing installations/plants. This philosophy applies specifically to onshore installations in respect to: •

Primary structure members and indoors structure members

•

Enclosures involved in Emergency Response or Escape, Evacuation and Rescue

•

Enclosed process areas and outdoors partitions

•

Process and storage, vessels and tanks

•

Safety critical process pipe work and Valve (ESDV’s)

PFP Systems shall be generally designed in accordance with the provisions detailed in SR EN ISO 13702, as applicable to onshore installations, in so far as that all systems and Rev:

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equipment shall be suitable for their intended environment and application and shall be supported with type approval certification evidence for their major components. The installation of PFP Systems shall be such that they protect the structure/equipment to a level appropriate to the expected fire or explosion loadings for a duration defined as appropriate for the given situation as determined by the Installation/Plant Fire and Explosion Risk Analysis (FERA). Risk Analysis shall be developed using the Methodology approved by Ministry of Interior trough Order 130/2006. 8.1

Risk Analysis

The decision to install PFP and the specification of the type of PFP to be implemented shall be made following a risk analysis of major hazards and their consequences to determine the degree of protection required for the duration of the hazard. In any case, the following rules shall apply: • PFP requirements for the purpose of life safety shall always be implemented, regardless of local regulation • PFP requirements for the protection of the environment shall be implemented, but with due consideration of local conditions • PFP requirements for asset protection are not mandatory and should be addressed by the project management team on a case by case basis The risk analysis should also identify the specific fire loading and duration, which will be used to specify the appropriate PFP rating, in terms of the following: •

Cellulosic Fires – “A” rated PFP

•

Hydrocarbon Pool Fires – “H” rated PFP

•

Hydrocarbon Jet Fires – “J” rated PFP

8.1.1 Functional Requirements The fire resistance provided by a PFP System is expressed in terms of the duration of protection that the system provides to the protected structure/equipment before the first critical behaviour is observed. The choice of PFP System should further consider the following factors: •

Pre-fire durability – resistance to weathering, vibration, chemicals, etc.

• Fire performance – flame spread characteristics, resistance to water deluge, smoke and toxic products emission, etc. •

Explosion resistance – reaction to overpressure and drag forces

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• Installation requirements – surface preparation, mode of application, applicator qualifications, environmental conditions, coat back, etc. •

The potential for corrosion under PFP

•

Weight constraints, where applicable

•

Certification – refer to Section 8.1.4

•

Fire and explosion hazards, as determined in the plant FERA

•

Cost-Benefit analysis

8.1.2 Performance Criteria In terms of Fire Rating, the structure, partition or equipment protected by a PFP System must satisfy the following three criteria under the conditions identified during the project FERA and for a prescribed duration suitable to achieve the safety goals identified for the plant: 1. Stability: the structure shall fulfil its load-bearing capacity (where applicable) throughout the fire exposure period 2. Integrity: partitions shall prevent the spread of flames and hot fumes throughout the fire exposure period. 3. Insulation: the unexposed side of partitions shall not reach surface temperatures in excess of a certain level throughout the fire exposure period. Insulation qualities are not always necessary. 8.1.3 Suitability The performance criteria and suitability of all PFP Systems shall be assured and supported by tests conducted by organisations authorized following the Methodology issued by

General Inspectorate for Emergency Situation (IGSU) and approved by Ministry of Interior. 8.1.4 Type Approval

Type approval of PFP materials is the issue of a certificate, based on the findings of the testing identified in Section 8.1.3 above, stating that the material certified is thus suitable for use in its intended application. Type approval certification is issued by independent organisations known as Certifying Laboratory (Authority). 8.2

Design Criteria

The design criteria for the PFP Systems shall be defined with the sole purpose of achieving the performance criteria of that which is being protected (refer to Section 8.1.3). 8.2.1 Limiting Core Temperature

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The stability of a structure is dependent on the materials limiting core temperature. The typically accepted limiting steel core temperature for steel is approximately 400oC however this is not definitive and depends on the material/material grade and the accepted testing methods of the associated testing laboratory. Structural heat-up calculations are an accepted alternative to testing for determining the limiting core temperature. 8.2.2 Maximum Allowable Surface Temperatures Similarly to the limiting core temperature for structures, those items of equipment deemed as requiring PFP will be addressed in terms of their maximum allowable surface temperature, i.e. the temperature at which critical behaviour is observed. The value of the maximum allowable surface temperature shall be equipment specific depending on the goal setting criteria for particular plant/project. 8.2.3 PFP Thickness The certificate of type approval for each PFP material will specify the required material thickness and other installation requirements (refer to Section 8.1.1) depending on the Fire Rating, fire type, limiting core temperature/maximum allowable surface temperature and will be specific to the PFP material under consideration. 8.2.4 Duration The required duration of protection (expressed in minutes) will depend on the safety goals identified in section 6.0 and the findings of the FERA and EERA. 8.3

Types of Available PFP Systems

Generally speaking, there are two generic forms of PFP material for use in the petrochemical industry, identified as being either active or inactive. Active PFP undergoes chemical and physical changes when exposed to fire whereas inactive materials do not. The following are common types of PFP materials provided for information purposes. The list is not exhaustive nor is it intended to recommend any particular material over another as the decision should be made depending on the intended application and engineering judgement. Epoxies Provide fire protection by active response to fire exposure, being either by Intumescences or Sublimation (see Section 2.0 – Definitions). Cementitious Inorganic cements provide fire protection firstly by means of dehydration of its water content, effectively absorbing heat, and secondly by acting as a physical insulation barrier.

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Magnesium oxy-chloride cements undergo thermal hydrogenation (the production of additional water) in the 130°C to 300°C range, effectively increasing its fire performance. High-density cement may be susceptible to spalling at elevated fire temperatures. Fibrous Utilise the physical properties of either ceramic or mineral fibres, which are prefabricated in panels or blankets and provide a physical insulation barrier from cellulosic type fires. Fibrous materials alone are not suitable for use as Hydrocarbon Fire protection. The chosen PFP System shall be type approved in accordance with Section 8.1.4 and its choice based on the full understanding of the performance requirements during both normal and fire events. 9. DESIGN CONSIDERATIONS The design of PFP Systems should take account of the following: • Life cycle costs as well as the capital cost, for example testing costs, false trip costs, commissioning and modification costs •

Human factors

• Selection and positioning of the correct field equipment suitable for the process and environmental conditions • The safety system shall provide protection for normal operation and for the conditions that may arise from an abnormal condition 10.

MAINTENANCE IN DESIGN

The PFP Systems shall be designed taking maintainability into consideration by simplifying maintenance and reducing maintenance costs where practical. There should be sufficient maintenance overrides to enable parts of the PFP Systems to be maintained and tested minimising operational down time. The PFP Systems should be designed to allow modifications and development to be implemented whilst minimising disruption to the process. 11.

DOCUMENTATION REQUIREMENTS

The following project documents should be produced as a minimum to cover the design of the safety system: Front end engineering design (FEED): •

Plant operational philosophy

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Installation Fire and Explosion Risk Analysis (FERA)

•

Design specification for the PFP Systems (hardware and software)

•

Hierarchy drawing

•

Safe charts as per API – RP 14C

•

Functional design specification of PFP Systems

Detailed design: •

Documents listed under FEED above

•

General arrangement drawings

• PFP System layout drawings identifying the type, extent and thickness of proposed PFP material •

Vendors fire certification evidence of the propose system

• Supporting calculations for heat transmission through structural members where appropriate • Redundancy/structural collapse analysis to determine those structural members that require PFP when subjected to elevated temperatures. 12.

CERTIFYING AUTHORITY REVIEW REQUIREMENTS

In the case where independent third part certification is required, the Certifying Authority (CA) will require as a minimum the following documents for review: •

Basis of Design Document

•

Functional design specification

•

PFP System layout drawings

•

PFP System interface details

•

PFP System calculations Hp/A values for structural members

•

PFP System type approval certification (as appropriate)

These should be issued to the CA in a timely manner to obtain approval before commencing construction.

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