FSR on Expansion and Modernization of the MOIN Refinery Project
12 Fire Protection
12.1 Overview
The project is a 50/50 joint venture, SORESCO S.A., between China National Petroleum
Corporation International Ltd. (CNPCI) and Refinadora Costarricense de Petroleo, S.A.
(RECOPE S.A.). SORESCO will implement an expansion project of the MOIN Refinery
from 1,000KTA (25,000BPSD) to 3,000KTA (60,000BPSD) to meet the domestic demand for
oil products.
The project mainly consists of the 2# atmospheric distillation unit (ADU ), 2# vacuum
distillation unit (VDU ), naphtha hydrotreating unit (NHT), continuous catalytic reforming
unit (CCR), delayed coking unit (De-coker), diesel hydrofining unit (DHF), VGO
hydrocracking unit, H2 production unit, isomerization and dry gas/LPG treatment unit, as
well as the auxiliary facilities and utilities.
12.1.1 Fire Hazard Analysis
The fire hazard analysis of units is conducted according to the specifications, production
process characteristics and the functions of related ancillary facilities, and the findings are
indicated in the tables below.
Table12.1-1 Fire Hazards in Process Units
No.
Unit Description
Unit capacity, kt/a
Fire hazard classification
2# ADU
2,000
2# VDU
1,500
NHT
550
CCR
500
De-coker
700
DHF
1,300
VGO Hydrocracking Unit
900
H2 Production Unit
25
Sulfur Recovery Unit
26
10
Dry Gas/LPG Treatment Unit
150
11
Isomerization
150
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FSR on Expansion and Modernization of the MOIN Refinery Project
Table12.1-2 Storage Tank Farm Fire Hazards
Tank
Qty,
capacity,
pc
m3
Tank type
Fire hazard
classification
External
Floating Roof
Tank
I-B
2000
Internal Floating
Roof Tank
I-B
1# Atmospheric
Kerosene
1000
Internal Floating
Roof Tank
II-A
To kerosene
hydrogenation section
1# Atmospheric
Residue
5000
stationary Roof
Tank
III-B
To VDU
1# Atmospheric
Naphtha
4000
Internal Floating
Roof Tank
I-B
To NHT
1# Atmospheric
Diesel
5000
Dome Roof
Tank
II-B
To diesel
hydrogenation section
2# Atmospheric
Kerosene
1000
Internal Floating
Roof Tank
II-A
To DHF
2# Atmospheric
Residue
5000
Stationary Roof
Tank
III-B
To VDU
2# Atmospheric
Naphtha
4000
Internal Floating
Roof Tank
I-B
To NHT
10
2# Atmospheric
Diesel
5000
stationary Roof
Tank
II-B
To diesel
hydrogenation section
11
Vacuum VGO
5000
stationary Roof
Tank
III-B
To hydrocracking unit
12
Vacuum
Residue
5000
stationary Roof
Tank
III-B
To coking section
13
Coker naphtha
1000
Internal Floating
Roof Tank
I-B
To diesel
hydrogenation section
14
Coker Gas Oil
2000
stationary Roof
Tank
II-B
To diesel
hydrogenation section
15
Coker VGO
1000
stationary Roof
Tank
III-B
To hydrocracking unit
16
Heavy naphtha
from
hydrocracking
1000
Internal Floating
Roof Tank
I-B
To CCR
17
Light naphtha
from NHT
1000
Internal Floating
Roof Tank
I-B
To isomerization unit
18
Heavy naphtha
from NHT
3000
Internal Floating
Roof Tank
I-B
To CCR
19
Naphtha from
NHT
1000
Internal Floating
Roof Tank
I-B
To NHT
No.
Tank
description
Medium
Crude
Storage
Tank
Crude
50000
Ethanol
Feedstock
Storage
Tanks
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Remarks
FSR on Expansion and Modernization of the MOIN Refinery Project
No.
Tank
description
Tank
Qty,
capacity,
pc
3
m
Medium
Tank type
Fire hazard
classification
20
Light slop tank
2000
Internal Floating
Roof Tank
III-A
21
Product gasoline
2000
Internal Floating
Roof Tank
I-B
22
Light naphtha
from NHT
1000
Internal Floating
Roof Tank
I-B
23
Heavy naphtha
from NHT
1000
Internal Floating
Roof Tank
I-B
24
Isomerized oil
1000
Internal Floating
Roof Tank
I-B
25
Reformate
2000
Internal Floating
Roof Tank
I-B
26
Aviation
kerosene
2000
Internal Floating
Roof Tank
II-A
27
Aviation
kerosene
1000
Internal Floating
Roof Tank
II-A
28
Aviation
kerosene from
hydrocracking
1000
Internal Floating
Roof Tank
II-A
29
Product diesel
10000
Dome Roof
Tank
II -B
30
Diesel from
hydrocracking
5000
Dome Roof
Tank
II-B
31
Diesel from
diesel
hydrogenation
5000
Dome Roof
Tank
II-B
32
Fuel oil
500
Dome Roof
Tank
II-A
33
Heavy sump oil
3000
Dome Roof
Tank
III-B
34
Product LPG
2000
Dome Roof
Tank
I-A
Remarks
To DHF Unit
Table12.1-3 Utilities Fire Hazards
No.
Unit Description
Functions
Fire hazard
classification
Raw Water Treatment Plant (Water Supply Pump
Station)
Plant-wide water
treatment
CCW
Process/fire pumps
DM Water Station (including Condensate
Polishing Station)
Circulating cooling
water treatment
WWT
Circulating cooling
water treatment
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FSR on Expansion and Modernization of the MOIN Refinery Project
No.
Unit Description
Functions
Fire hazard
classification
Water Supply/Drainage Pipeline System
Process/sanitary water
treatment
Table12.1-4 Fire Hazards from Process & Service Facilities
No.
Unit Description
Fire hazard classification
Mechanical, Electrical and Instrument Workshop
Central Lab
Environment Monitoring Station
3
Administration Building
Staff Living Quarters
Chemical Warehouse
Table12.1-5 Properties of Main Inflammable and Explosive Materials
Material
description
Spontaneous
Explosion limits,
Flash point,
v%
ignition point,
Explosive hazard
classification
Group
Class
Fire hazard
class
Crude oil
1.18.7
-6.6732.2
350
T3
I-B
Dry gas
1.01.5
<66
650750
T1
LPG
313
<68
430446
I- A
Naphtha
1.26.0
36177
480510
T3
I-B
Gasoline
1.15.9
<20
255530
T3
I-B
Diesel
1.54.5
5090
350380
T3
IIA
III-A
Kerosene
0.6
<45
223290
T3
II-A
LPG
2.259.65
<-70
426
T2
I-A
Residual oil
1.26.0
50158
300350
T3
H2
4.075.6
4.174.2
570
T1
IIC
H2S
4.345
4.345.5
246
T3
IIB
N2
1625
1525
650
T1
SO2
T1
>180
232
T12
12.1.2 Firefighting System and Policy
(1) To observe the principle of the Prevention First and Combining Prevention with
Firefighting to Minimize Fire Damages and Ensure Personal and Property Safety.
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FSR on Expansion and Modernization of the MOIN Refinery Project
Strictly implement relevant codes for fire protection design and take proper
precautions against fire to prevent and mitigate fire damages;
(2) To select disaster resistance and fire prevention technologies; to introduce advanced
and proven disaster resistance and prevention technologies to provide reliable facilities,
advanced technologies, rational engineering economics and practical operability;
(3) To determine firefighting facilities based on such factors as plant operation capacity,
fire hazards and available surrounding combined efforts to extinguish fires; and
(4) To select a fire protection system with combined private fire brigades and voluntary
fire brigades; to provide necessary emergency firefighting facilities for posts in support
of the project.
12.2 Configuration of Firefighting Facilities
As shown in the following table, the main firefighting facilities will be located in each of
plant spaces.
Table12.2-1 Main Firefighting Facilities for Plant Areas
Water
Foam fire
Capacity
Fire
Fire
Fire
spray fixed
extinguishing
hydrant monitor
extinguisher
kta
system
system
No.
Unit Description
2# ADU
2,000
2# VDU
1,500
NHT
550
CCR
500
De-coker
700
DHF
1300
VGO Hydrocracking Unit
900
H2 Production Unit
25
SRU
26
10
Dry Gas/LPG Treatment
Unit
150
11
Isomerization
150
12
Tank farm
12.2.2 Firewater Supply System
12.2.2.1 Brief Description of the Existing Firewater System
The existing firefighting facilities are available in service, including fire hydrants, fire
monitors, stationary sprinklers & cooling systems, low-expansion foam extinguishing systems,
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FSR on Expansion and Modernization of the MOIN Refinery Project
etc.
The max firewater feed rate to existing refinery LPG spheres is 2,270 m3/h; the max
firewater feed rate to process plant areas is 1,360m3/h.
Table12.2-2 Existing Refinery Firewater Feed Rates
No.
Unit Description
Firewater feed rate, m3/h
Firewater feed rate to existing refinery LPG spheres
2270
Firewater feed rate to existing refinery firefighting system
1360
12.2.2.2 Firewater Consumption
For the upgraded MOIN refinery, it is assumed that two fires occur at the same time, one
would take place in the plant area, where the firewater consumption is the maximum, the
other would take place in the auxiliary production facilities. Firewater consumptions will be
designed based on the water feed rates to firefighting facilities located in areas. The maximum
firewater consumption may occur in the water spray fixed system in the tank farm. A design
margin at 200m3/h is considered on the basis of the total firewater consumption by fixed foam
fire extinguishing systems, fire monitors and fire hydrants. Considering that the max firewater
consumption by the tank farm is at 3,300m3/h, plus the 180m3/h firewater consumed by
auxiliary facilities, the firewater demand for the project is designed at 3,480m3/h. The inflow
pressure is considered not less than 0.8MPa(G), this represents an extreme worst case,
assuming a 6h fire duration.
12.2.2.3 Firewater Sources
A HP firewater pumping station is design for supporting the project, where the firewater
is taken from the Moin River to the HP firewater systems for the new process units. The HP
firewater pump station is designed to have a supply flow rate at 3,480 m3/h for a fire lasting
for 6 hours.
The fire pumping station is provided with a fire electric fire pump with a design flow rate
of 1,160m3/h & a lift of 100m. Three diesel pumps are installed, i.e., the two in operation and
the other standby with a design flow rate of 1,160m3/h per set and a lift of 100m. In case of a
fire, the related firefighting pipe network has a rapid pressure drop, and the HP electric fire
pumps activates. In case of a failure on the electric fire pump or increased firewater flow, the
diesel pumps will activate.
Two jockey pumps (1 operating and 1 spare) will be installed with a design flow rate of
50m /h and a lift of 120m.
3
12.2.2.4 Firewater System
A firewater system consists of a firewater supply system and indoor fire hydrants,
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FSR on Expansion and Modernization of the MOIN Refinery Project
outdoor hydrants, stationary hand-operated water guns, and fixed water spray systems. The
firewater is designed to cool the affected equipment and areas, where may be exposed to the
thermal radiation to protect escape exit, and to control & extinguish the fire partially.
12.2.2.5 Foam Fire Extinguishing System
A stationary low expansion foam fire extinguishing system is installed in the crude tank
farm. A stationary low expansion foam fire extinguishing system will be provided in the tank
farm. A loop foam pipe network will be located around the tank farm. The foam pipe network
will be equipped with a number of outdoor above-ground foam hydrants,with hose cabinets
for rapid fire extinguishing.
A balancing pressure foam proportioner is selected for the foam fire extinguishing
system of the storage tanks. The balancing pressure foam proportioner will be provided with a
5m3 foam concentrate storage tank to store the 3% aqueous film-form foam. The mixed foam
liquid flow rate is about 64L/s.
Portable foam fire extinguishing system should be installed in the plant if pool fire may
happen.
12.2.3 Steam Fire Smothering System
A fixed extinguishing system or semi-fixed extinguishing system may be provided in a
closed pump room or a compressor room; however, where the accident may occur, steam
must not be used for extinguishing.
12.2.4 Gas Fire Extinguishing System
An inergen gas fire extinguishing system is provided in the control room.
12.2.5 Fire Extinguishers
Sufficient portable and wheeled fire extinguishers will be provided in the plant area;
portable carbon dioxide fire extinguishers will be provided in control rooms and substations
in response to any possible fires.
12.2.6 Detection and Preaction Systems
Combustible gas detection annunciators will be provided in sites where combustible
gases may build up. Portable poisonous gas monitors will be provided in the places and
around the equipment where toxic gases may exist and alarm signal is sent to the master
control room.
Flammable gas detection system (FGDS for short) will be provided independent of the
process control system (DCS) and the safety instrumented system (SIS).
12.2.7 Project-wide Fire Alarm System
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FSR on Expansion and Modernization of the MOIN Refinery Project
An automatic fire alarm system will be provided in the plant area for early monitoring,
forewarning, equipment detection, display, alarm, operating condition, accident record,
maintenance, and access control.
This system consists of the general alarm panel (fire station), fire alarm control display
panel (CCR), sector fire alarm control display panel (in buildings or rack rooms with fire
linkage systems), sector fire alarm panel (in buildings or rack rooms without fire linkage
systems), smoke detectors, heat sensitive detectors, manual pull station and fire emergency
paging system. The front end alarm devices are designed to use the address code. Flame
retardant cables will be used as wiring cables of the fire alarm system.
Alarm signals from such terminal equipments as detectors and alarm buttons of units in
the plant area, tank farms and buildings are sent to the local sector fire alarm control panel or
sector fire alarm panel. Such controlled equipments as the solenoid valves of preaction valves
and firefighting equipments to the smoke exhaust fans and vent ducts shall be incorporated
into the local sector alarm panels, where the signals of alarm, control and the operating
conditions of firefighting equipments are sent from the site-wide fire alarm control platform
to the fire departments control room and CCR. All controllers for the firefighting equipment
shall control the functions of that equipment locally.
Sector fire alarm control panels or sector fire alarm panels will give signals to fire alarm
control display panels in CCR. The communication lines between fire alarm control display
panels, sector fire alarm control panels and sector fire alarm panels will be routed along
bridges or laid underground. Sector fire alarm control panels will be installed in attended
areas.
The control room shall be provided with automatically-actuated gas extinguishing
systems. Bus fire detectors will be provided in CCR, substations, laboratory(s), corridors,
passways, offices, halls, air conditioning facilities, power distribution rooms, maintenance
shops and other areas for protection purpose. Manual alarm buttons shall be installed at the
main exits at each floor of the buildings, the walk-around access of plant area and by the
waysides around tank farm. Explosion-proof flame detectors will be provided for hot oil
pumps in the plant area. Resettable thermal static cables or thermometric cables shall be
installed along the cable interlayers. Such devices as optical fiber thermoscope and fiber
grating will be installed on the crude storage tanks.
The heat sensitive detectors, smoke detectors and manual pull stations shall be of the
intrinsic safety explosion-proof type or flameproof type. Low contributed parameter cables
will be used between intrinsically-safe equipment and safety barrier.
Sirens or audible-visual annunciators provided for the process units may be linked with
fire alarm panels in the area to give audible alarms. Audible-visual annunciators are provided
at main walk-around accesses, where the installation heights will be determined accordingly.
Other warning facilities will be selected according to environmental requirements to be
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FSR on Expansion and Modernization of the MOIN Refinery Project
appropriate to environmental requirements.
Automatic fire alarm systems will be interconnected with CCTV systems, DCS and
paging system, where the CCTVs linkage interfaces will be located in CCR. Communication
interfaces with DCS will be located on monitoring devices or sector fire alarm control panels
or sector fire alarm panels in tank farm.
12.3 Fire Station
12.3.1 Existing local firefighting facilities
Two existing fire engines are provided for the fire station at the project site; however,
they have been used for nearly 20 years. Therefore, there is considerable concern, i.e.,
corroded engines and non-workable foam tenders.
12.3.2 Fire Station
In view of existing fire station, and the appropriate firefighting facilities to be installed at
the battery limits, more fire vehicles shall be provided for the project. Three new fire engines,
four parking spaces are designed for the fire station, one of which will be provided with a
service pit. They are provided with necessary firefighting equipments, such as PPE for
firefighters, fire forcible entry tools, means of communications and so forth.
Table12.3-1 Fire Engines
No
Vehicle description
Qty,
pc
Specifications
Nominal operational height: 28m
Elevating platform fire
truck/water tower fire
truck
Heavy-duty water
tanker-foam universal
fire truck
Total
Hopper load: 0.4 t
Fire monitor capacity: 100L/s (50L/s x2)
Warning devices, communications facilities, lighting fixtures and control
panel to be provided in the basket
Foaming capacity: 6,000L; Water holding capacity: 12,000L
Mixed foam flow rate: 60 L/s
Fire monitor capacities: water monitor: 80 L/s; foam monitor: 48 L/s
Fire pump capacities: 70L/s @ 1.0MPa; 35L/s @ 2.0MPa
12.4 Investment in Firefighting Facilities
The investment in the firefighting facilities for the project will be used for the following
purpose:
A firewater system consists of firewater pump houses, firewater storage tanks, fire
pumps, jockey pumps, HP firewater pipes, valves and valve wells, indoor/outdoor ground type
fire hydrants, fire water monitors and box type hydrants, firewater supply risers, sprinkler
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FSR on Expansion and Modernization of the MOIN Refinery Project
systems cooling LPG storage tanks, automatic water sprinkler system and so on;
The foam fire extinguishing system mainly includes a separate foam station, a balancing
pressure foam proportioner, ARFFF foam concentrate, foam mixture pipes and valves, foam
hydrants and foam generators, and so on.
The Inergen gas fire extinguishing system mainly includes an inergen extinguishant
cylinder battery, a fire detection system, system initrializaion control system, gas
extinguishing system piping and gas nozzles.
Other fire protection facilities mainly include steam smoothering lines, semi-fixed steam
connection, portable and wheeled dry powder fire extinguishers and portable carbon dioxide
fire extinguishers;
Fire alarm and combustible gas alarm systems mainly include the manual fire alarm
system, automatic fire detecting devices for temperature-sensitive cables, fire detectors,
combustible gas detectors, their connecting cables, fire and combustible gas alarm display and
control panels.
Refer to Chapter 17 - Economics Evaluation - for the specific costs of firefighting
facilities.
12.5 Design Regulations, Codes and Standards for Fire Protection System
NFPA 1 Uniform Fire Code
NFPA 10 Standard for Portable Fire Extinguishers
NFPA 11 Standard for Low-, Medium-, and High-Expansion Foam
NFPA 13 Standard for the Installation of Sprinkler Systems
NFPA 15 Standard for Water Spray Fixed Systems for Fire Protection
NFPA 20 Standard for the Installation of Stationary Pumps for Fire Protection
NFPA 30 Flammable and Combustible Liquids Code
NFPA 101
Life Safety Code
NFPA 2001
Standard on Clean Agent Fire Extinguishing Systems
Please refer to relevant China fire protection codes and standards if necessary.
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