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

PROCESS FLOW

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.

ON SITE EMERGENCY MOCK DRILL

EMERGENCY VEHICLES

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)

Phast is the world’s most comprehensive process industry hazard analysis software tool for all stages of design and operation. The software examines the progress of a potential incident from the initial release to far-field dispersion including modeling of pool spreading and evaporation, and flammable and toxic effects

PUBLIC REACTION MAY TO ANY EVENT

External Communication Plan Public Visit ( Neighbor Community, Colleges, Schools ..etc) Authority Involvement (Public Authority Civil defense,MECA,SFZ ) DNV Phast Study (Storage Tank Study) Communicate the ERP with community.