FIRE PROTECTION SYSTEM FOR LARGE CHEMICAL STORAGE

BY: MOHAMMED AL MUJAINI

HSE MANAGER
SALALAH METHANOL
SALALAH METHANOL COMPANY
Organisation:

Salalah Methanol Company LLC (SFZ)

Location:

Salalah, Sultanate Of Oman

Process Technology:

Low Pressure Methanol by Johnson &

Matthey Catalyst Technology

From Natural Gas to Methanol (Liq.)

Scale: A Day 3,000 TON Methanol

Site Area Area: 489,100 m2

Man Power: 250

Construction Period: 3 Years

Operation since 10 April 2010

 LEGAL QUIREMENTS

Final Environmental Permit from MECA

Civil Defence Permit for Operating Plant

Ministry of Health

Permit from Salalah Free Zone

Chemical storage and Handling,

 METHANOL
Hydroxymethane, Methyl alcohol
Methyl hydrate, Wood alcohol
wood naphtha, wood spirits
Carbinol
CH3OH
Often abbreviated MeOH

Physical Properties 3
Clear, colorless liquid
1 0
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.
PROCESS FLOW
 SMC PLANT LAYOUT
Non Technical Building Area

FTG

Admin Bldg
HSE Bldg.
Sec.
W/H
S/S

Utility Area
LAB
Control Bldg

Storm Water
Pond
Fire Water
Pond
Methanol
Storage Tank
54,000m3 x 2
Storage Area Reformer Pkg. ETP Desal Unit

Demi Water
Tanks

SynGas
Comp

Feed Gas Electro Chlorination Unit

Comp
Sea Water
MeOH Distillation STG Cooler

MeOH Converter Power Gen

S/S
Boiler
Air Comp

Main S/S
Flare
N2 Plant

Methanol Process Area

Flare Area
Area : 489,100 m2
 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) Discharge Pressure
(m3/hr) (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
Emergency Alert
Telephone,, Plant Radio, PA System, MCP,
F & G Alarm, Person First on Scene

Notification by providing Information to

Panel Operator on 23218999

Medical Emergency Fire, Gas, Chemical Emergency Other Emergency

Alarm Confirmation by IC /designee

Decision Making ERC

ECC CEO , Dy. CEO & Managers
ECC Coordinator
Head of Production / Shift Sup (Utility)

Communication to/from
OOC and Shareholders
Information to/from Neighboring
Plants, Regulatory & Vicinity

ERT Members (29) Incident HSE Supervisor (1)

EMT Members (08) Commander Fire Chief (1)
External Emergency Aid Industrial Nurse (1)

Action to combat situation All CLEAR

 EMERGENCY RESPONSE TRAINING

NFPA 1001: Fire Fighter Level -1

NFPA 472: HAZMAT responder Awareness

Fire & Safety Engineering College (Muscat,

Oman)

International Fire Services Accreditation Emergency Medical Team members

Congress, USA (IFSAC) MEDIC FIRST AID CarePlus CPR and
National Fire Protection Association, USA AED Program.
(NFPA)
American Safety and Health Institute (ASHI),
Institute of Occupational Safety & Health
(IOSH, UK)
Institute of Fire Engineers (UK).

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
FIRE RISK MANAGEMENT FOR METHANOL STORAGE TANK
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.
 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 dont breathe in air.
In case of over-pressurization, they breathe
out to air for tank safety.
FIRE & GAS ALARM, COMMUNICATION SYSTEM
UV/IR Detector 2 Gas & Smoke Detectors 6
D
E
T
E
C
T
I
O
N

Manual Alarm Call Point 20

C
A
L
RADIOS PROVIDED TO CONCERN PLANT EMPLOYEES
L AND
P
O PA SYSTEM ALSO PROVIDED IN PLANT
I
N
T
S
I
Warning Lamp 2 sets Motorized Siren / PA Speaker

W
A
R
N
I
N
G
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 worlds 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.