Loss and Prevention oil&gas

ABU DHABI POLYMERS COMPANY LIMITED

(BOROUGE)

BOROUGE CONTRACT NO.

JVP-EU-003

BOROUGE DOCUMENT NO.

PGS-PU-113

REV. NO. EB

ETHYLENE, UTILITIES, OFFSITES AND EXTERNAL INTERCONNECTIONS

PAGE 1 OF 39

ALLIANCE BECHTEL LINDE

THE DESIGN OR PART THEREOF CONTAINED IN THIS DOCUMENT WAS DEVELOPED FOR BOROUGE AND MAY BE UTILISED BY BOROUGE FOR ANY PURPOSE RELATING TO THE

CONSTRUCTION, MAINTENANCE OR OPERATION OF THE PROJECT. INTELLECTUAL PROPERTY RIGHTS IN THE DESIGN OR INFORMATION CONTAINED HEREIN REMAINS THE

PROPERTY OF ALLIANCE BECHTEL LINDE.

ELECTRONIC DOCUMENTS, ONCE PRINTED, ARE NON-CONTROLLED AND MAY BECOME OUTDATED

BOROUGE PETROCHEMICALS PROJECT

PROJECT NO. ABL 24168

PHILOSOPHY

for

LOSS PREVENTION

ABL NO. 24168-GGH-3SS-USSE-00002

REV DATE DESCRIPTION ORIG ORIG

DATE

CHKD APPR APPR DATE

A ISSUED FOR CLIENT COMMENTS DH TGW KHQ

AB 11/03/99 RE-ISSUED FOR CLIENT COMMENTS DH TGW KHQ

D 16/04/99 RELEASED FOR DESIGN DH TGW KHQ

E 13/5/99 RELEASED FOR CONSTRUCTION DH GK ABM

EA 21/7/00 RE-ISSUED FOR CONSTRUCTION AM AM ABM

EB RE-ISSUED FOR CONSTRUCTION


ABL No: 24168-GGH-3SS-U000-00002 Rev. No. EB Page 2 of 39

CONTENTS

1. INTRODUCTION ................................................................................................................... 3 2. BASIS OF DESIGN ................................................................................................................ 4

3. DESIGN CRITERIA ............................................................................................................... 4 4. PLANT ORIENTATION AND LAYOUT ............................................................................. 7 5. AREA CLASSIFICATION ..................................................................................................... 8 6. MEANS OF ESCAPE............................................................................................................ 10 7. PASSIVE FIRE PROTECTION ............................................................................................ 11

8. PROCESS SAFETY SYSTEMS ........................................................................................... 15 9. FIRE AND GAS DETECTION AND ALARM SYSTEMS ................................................. 16 10. ACTIVE FIRE PROTECTION ............................................................................................. 26 11. DRAINS SYSTEMS .............................................................................................................. 33

12. ELECTRICAL SAFETY ....................................................................................................... 34 13. HVAC SYSTEMS ................................................................................................................. 34 14. FLARES AND VENTS ......................................................................................................... 36

15. HAZARDOUS MATERIALS ............................................................................................... 36 16. NOISE AND VIBRATION ................................................................................................... 37 17. PERSONNEL PROTECTION............................................................................................... 38 18. EMERGENCY PREPAREDNESS ....................................................................................... 39

19. ATTACHMENTS: ................................................................................................................. 39



1. INTRODUCTION

1.1. Safety and Loss Prevention in Design

1.1.1. This document describes the loss prevention and safety design criteria to be applied to the design of the facilities. The purpose of the document is to ensure

that the same philosophy and design approach is applied to all aspects of the

development, and it forms an integral part of the Safety, Health and

Environmental (SHE) Plan for the project. The Project SHE Plan is fully

described in Document No.PPM-DU-181.

1.1.2. The engineering and design of the facilities shall ensure inherent safety by specific attention to the following:

ESD and EBD System (Refer to Documents No. PGS-PU-111 and 11-PU-101-0002.)

plant layout

hazardous area classification

safeguarding by instrumentation and control

start-up, shutdown and blowdown

fire and gas detection

fire protection systems

overpressure protection systems

equipment isolation for maintenance

specification breaks

equipment design

vents and flares

drains

control building requirements

escape routes

fire and safety equipment

personnel protection

HP/LP Interface

Operating Manuals



2. BASIS OF DESIGN

The principal objectives are to ensure an inherently safe design of the plant and facilities

with due regard to the climatological and environmental conditions to;

a) Minimise the risk and consequences of an accidental event, such that the risk to local communities is negligible and that to on-site personnel is as low as is

reasonably practicable:

b) Minimise the potential for hazardous occurrences.

c) Ensure a safe working environment for personnel.

d) Ensure adequate means of escape are provided.

e) Maximise the benefits of protection measures, such as layout and separation of identified non-hazardous and hazardous areas.

f) Provide sufficient safety devices and redundancy to isolate and minimise uncontrolled releases of flammable and toxic liquids and gases.

g) Provide appropriate fire protection systems to control any reasonably foreseeable fire which could develop during normal operations.

h) Minimise the potential for pollution of the environment from accidental spills, venting or flaring of hazardous materials.

3. DESIGN CRITERIA

3.1. General

3.1.1. The safe design of the facilities shall be achieved by applying the requirements of identified statutory codes, and relevant international codes, standards and recommended

practices as listed in section 3.2, together with a structured hazard identification and

assessment programme. Details and schedule of the hazard identification and assessment

programme are provided in the project SHE Plan.

3.1.2. The purpose of the hazard identification and assessment activities is to ensure that the hazards associated with the operation of the facilities are identified at the

earliest stage in order that measures can be taken to either eliminate them, or to

minimise them and their effects. Hazard identification will be by hazard and

operability (HAZOP) studies; coarse HAZOP will be performed early in the

design activities, to ensure that major hazards are identified, whilst a detailed

HAZOP will be performed at the end of the basic design. The HAZOP study

technique is defined in Borouge procedure Hazard Studies; PGS-PG-001.



3.1.3. Hazards identified during coarse HAZOP (QRA) will be examined as part of the formal safety assessment programme; the results of the assessment will include

design accidental loads for selected buildings and structures, where appropriate.

3.1.4. To ensure a high degree of reliability is provided by the fire and gas detection, and alarm systems and that the fire protection systems perform their required function

during emergency conditions, there shall be spare equipment or redundancy so

that a single failure in the systems would be unlikely to cause critical loss of

protection.

3.2. Codes and Standards

3.2.1. Codes and standards to be applied to the design works will be applied in the following order of precedence:

a) Abu Dhabi/UAE codes and standards ;

b) Employer/ADNOC standards;

c) Internationally-recognised design codes and standards (e.g. API recommended practices, NFPA codes, IP Codes of Practice);

d) ABL design standards and practices.

3.2.2. The codes and standards of Abu Dhabi represent a statutory obligation, and the design of the facilities must comply with the specified requirements unless a

waiver is granted. Compliance with these codes will, however, be taken as a

minimum standard; where Company or Contractor codes or international/industry

best practices indicate a higher standard or system performance this shall

preferentially be applied.

3.2.3. Safety-related codes and standards to be applied to the project are detailed in Table 3. Where no local, company, or internationally recognised standard is

available the contractor standards and design practices will be applied as

necessary.

3.3. Design Documents

A comprehensive range of Fire and Safety design specifications, data sheets and design

drawings shall be developed during the various phases of the Project, in line with the

philosophy laid down in this document.



TABLE 3

International Codes and Standards

International

Standard

Title

IEC 79 Electrical Apparatus for Explosive Gas Atmospheres.

BS 476 Fire Tests on Building Materials and Structures.

IP Part 15 Institute of Petroleum Area Classification Code for

Petroleum Installations.

API RP 520 Recommended Practice for the Sizing, Selection and

Installation of Pressure Relieving Devices in Refineries

(Parts 1 and 2)

API RP 521 Recommended Practice for Pressure- Relieving and

Depressuring systems.

API RP 2218 Fire Proofing Practices in Petroleum and Petrochemical

Processing Plants.

NFPA 10 Portable Fire Extinguishers

NFPA 11 Low Expansion Foam

NFPA 12 Carbon Dioxide Extinguishing Systems

NFPA 13 Installation of Sprinkler Systems

NFPA 14 Installation of Standpipe and Hose Systems

NFPA 15 Water Spray Fixed Systems for Fire Protection

NFPA 16 Installation of Deluge Foam-Water Sprinkler Systems and

Foam-Water Spray Systems

NFPA 20 Installation of Centrifugal Fire Pumps

NFPA 22 Water Tanks for Private Fire Protection

NFPA 24

Installation of Private Fire Service Mains and Their

Appurtenances

NFPA 30 Flammable and Combustible Liquids Code

NFPA 72 National Fire Alarm Code

NFPA 101 Life Safety Code

NFPA 2001 Clean Agent Fire Extinguishing Systems

OSHA Occupational Safety and Health Administration

IRI IM.2.5.2 Oil and Chemical Plant Layout and Spacing

NFPA 25 Inspection, Testing and Maintenance of Water Based Fire

Protection Systems

NFPA 59A Production, Storage and Handling of Liquefied Natural

Gas

(The above are in addition to PGS project specifications)



4. PLANT ORIENTATION AND LAYOUT

4.1. General

4.1.1. The primary consideration when laying out hydrocarbon processing plant is its impact on the public and the environment. Economics also affects the layout

of the facilities therefore there must be balance between the incremental

benefit resulting from greater spacing and additional costs.

4.1.2. Of primary importance are local laws and regulations concerning fire protection design, public safety and environmental protection. Legal

requirements must be followed unless specific approvals of deviations are

obtained from the enforcing authority. The local codes and standards to be

applied, include specific requirements regarding minimum acceptable

separation distances. (IRI spacing rules).

4.1.3. The plant layout and design shall reflect the results and recommendations of the Preliminary Hazard Assessment and the basic guidelines given in this

document.

4.2. Layout Principles

The following principles governing plant layout shall be taken into account when

designing the facilities for the Project:

a) Adequate separation between flammable hydrocarbons and ignition sources.

b) Adequate separation between hydrocarbon handling areas and emergency services, main safety equipment, escape routes, and areas considered non

hazardous.

c) Maintenance of structural integrity during a hazard condition to avoid escalation and provide sufficient time to enable orderly evacuation to be

achieved.

d) Control facilities and related buildings shall be preferentially located so that they are largely unaffected by incident heat radiation or explosion

overpressures resulting from credible accidents. Where this cannot be

achieved, construction of buildings shall be sufficient to withstand the effects

of accidental loads. If construction requirements are excessively onerous, risk

assessment techniques may be applied to establish appropriate protection

requirements.

e) Adequate maintenance and access to all areas for fire fighting and associated vehicles.

f) Sufficient means of escape to enable efficient evacuation from all areas to designated assembly points, under a hazard condition.

g) Suitable drainage and spill control.



h) Orientate the plant such that prevailing winds direct flammable and toxic gases away from safe areas or inhabited property outside the boundary fence.

i) Design the plant so that the detrimental effects of natural forces are minimal.

j) Flares and vents are located so as to cause minimum interference or hazard to plant and personnel.

k) Orientate the plant such that prevailing winds will direct a flammable gas release away from furnaces.

l) Vehicle Access (noting the constraints of hazardous area classification).

4.3. Requirements for Layout and Arrangement

In order to ensure the requirements of the relevant codes and standards are satisfied, a

separate plant layout specification has been prepared, Piping Design and Plant Layout, which shall be used for establishing intra and inter-plant spacing and equipment arrangement. This has employed the most stringent of the local, Company

and International codes which have been identified.

For environmental considerations a separate specification has been prepared ,

Environmental Philosophy

5. AREA CLASSIFICATION

5.1. General

5.1.1. The facilities shall be classified according to the likelihood of flammable gases and liquids being released, and the hazards which they would present.

The classification shall be carried out in accordance with Institute of

Petroleum Model Code of Safe Practice Part 15 Area Classification Code for Petroleum Installations (IP 15).

5.1.2. During the course of area classification particular attention shall be given to the following:

Equipment and building air intakes and exhausts

Cold vents

Elevated pipework

Battery storage

Ventilation and pressurisation of buildings

Drains

Fired Heaters and Boilers (considered non-hazardous)

Flares

5.1.3. The following areas shall be defined as non-hazardous by location.

Control and electrical rooms



Normally manned buildings

Firewater Pump Houses

Emergency Diesel Generator Rooms

Fire Station

5.1.4. Other general buildings may be defined as non-hazardous by positive pressurisation from an HVAC system.

5.2. Equipment Selection

5.2.1. Electrical Equipment

Electrical equipment installed in a hazardous area shall be suitable for use in

the appropriate area classification and shall:

Comply with the requirements of IEC 79 & BS 5345.

Be certified by a recognised international authority, e.g. BASEEFA, CENELEC

5.2.2. Mechanical Equipment

All mechanical equipment installed in hazardous areas shall be of a type which

will ensure that hot surfaces are insulated, is non-sparking and adequately

protected against the generation of a static charge.

5.2.3. Vehicle Access

Vehicles and mobile equipment that constitutes a potential ignition source

shall be prohibited from process units and hydrocarbon storage areas unless

suitably protected and specifically authorised.

5.3. Ventilation

To minimise the classification of a hazardous area, adequate ventilation is necessary.

In unrestricted open areas a natural airflow across the area is considered to be

sufficient by area classification codes to be applied. For enclosed areas in which

flammable hydrocarbon processing equipment is to be installed, there are specific

ventilation requirements.

5.4. Area Classification Drawings

Area classification drawings and schedules shall be prepared in accordance with IP 15

and shall include the following information:

Identification of sources of release

The classification and extent of all hazardous zones

Notes regarding selection of electrical equipment

Differentiate between lighter and heavier than air releases



6. MEANS OF ESCAPE

6.1. General Requirements

The general requirements for means of access and egress are detailed in the codes

listed in section 3.1 and provide information on necessary minimum clearances

between equipment items, also horizontal and vertical clearances.

6.2. Escape Routes

6.2.1. At least two escape routes shall be provided from all areas, and buildings throughout the plant. Where the distance from any point within an enclosed

area exceeds 12 metres, there shall be two exits from the room or enclosure.

For main corridors/passage ways within two hour fire rated buildings, the

maximum permitted walking distance shall be 25 metres. Buildings of a lower

fire resistance shall have shorter distances in line with the appropriate code.

For blind or dead end passageways, the maximum distance to an exit shall be

8 metres.

6.2.2. Escape routes in process areas shall take the most direct route from the immediate hazard to an area of lesser hazard and shall avoid directing

personnel escaping from a non-hazardous area through a Zone 1 or Zone 2

hazardous area to a place of safety.

6.2.3. Escape routes shall be designated as follows, based on the layout specification prepared for this project:

a) Primary escape routes from all areas to assembly points shall have a minimum clear width of 1500 mm.

b) Secondary escape routes where escape is in one direction only shall have a minimum clear width of 1000 mm.

c) Stair widths on primary escape routes shall be 1500 mm.

d) The clear height of any escape route shall be 2150 mm.

e) Tank stairs are considered to be for maintenance only in normally unmanned areas and are excluded for the above, but should be 750mm

wide, as a minimum within handrails.



6.2.4. The configuration of the primary escape routes shall provide adequate room for fire and rescue teams to operate unhindered. Where changes in elevation of

escape routes occur, ramps or stairways shall be provided. The minimum clear

width of stairways shall generally be the same as the escape route they serve.

6.2.5. Fixed ladders specifically for escape purposes are only required as follows:

a) Escape from access platforms less than 5m long or from cranes, towers, etc., where the use of fixed ladders is common practice.

b) Secondary escape from an elevated process area which has a main escape stairway.

6.2.6. Every escape route and assembly point shall be readily accessible, unobstructed and well marked. Each route is to be provided with adequate

lighting and the routes are to be kept clear at all times. Equipment and fixtures,

if located along escape routes, shall be recessed so as not to reduce the

effective width of the passageway.

6.2.7. All doors on escape routes shall be easily opened from either side and shall not be capable of being permanently locked except by frangible elements. All

doors shall be illuminated by an emergency lighting system. Hinged doors

shall generally open in the direction of escape. Doors which open out on to an

escape route shall not reduce the escape route width below the minimum

required.

6.3. Escape Route Markers

Direction arrow markers shall be strategically positioned along escape routes where it

is necessary to guide personnel to assembly points.

7. PASSIVE FIRE PROTECTION

7.1. Fireproofing Zones

Selected structures located within a Fireproofing Zone (FPZ) shall be fireproofed,

except in the case of specific equipment as described in the following. An FPZ shall

only be applied to a plant or system with a maximum operating inventory of more

than 5 metric tonnes of flammable product. In this context, a system is the smallest volume of piping and equipment (including vessels) that can be blocked in in the event of a fire.

For liquid pool fires, the FPZ is a volume with a cylindrical shape. The cylinder shall

have a radius of 6m from the Potential Source of Leakage (PSL) and a height of 9m

above the Hazard Level (HL).

For liquid or vapor torch fires, the FPZ is a volume with a spherical shape. The radius

of the sphere shall be 3m measured from the PSL.



7.1.1. Structures Supporting Equipment

Steel structures located within an FPZ shall be fireproofed when the supported

equipment contains a total of more than 2 metric tonnes of flammable product,

has a total mass (including contents) of more than 10 metric tonnes, contains

toxic material or when sudden failure is likely to cause danger to personnel or

may lead to consequences beyond the property limit, including environmental

damage.

Steel structures within an FPZ supporting air coolers shall be fireproofed if the

air cooler contains a total of more than 1 metric tonne of flammable product or

the total mass of the air cooler(s) supported by the structure exceeds 2.5 metric

tonnes (including contents).

Columns, beams, and any members within the FPZ designed for the purpose

of reducing the effective buckling length of the columns shall be fireproofed.

Stairways, walkways, and platform designed mainly for live loads and top

surfaces of beams supporting floor plates, gratings, or equipment will not be

fireproofed.

7.1.2. Steel Pipe Supports

Criteria

Individual pipe supports and steel structures overhead piping located in an

FPZ shall be fireproofed if one or more of the following apply:-

The pipe is a flareline or an emergency depressurizing vent line.

The pipe connected to equipment which would be severely damaged by

additional nozzle loading in the event of loss of pipe support.

The pipe runs beneath an air cooler whose steel support structure is

fireproofed (including horizontal members).

The pipe carries fire-fighting water an/or other utilities which would reduce

the fire-fighting capability in the event of loss of support.

The pipe is an instrument air line or hydraulic control line whose loss would

interfere with the ability to shutdown the plant.

Extent of Fireproofing

Columns of piperacks and pipe supports shall be fireproofed from hazard level

up to 0.3m below the lowest horizontal member of the structure.

Bracing

Diagonal bracing for resisting only lateral wind or seismic forces shall not be

fireproofed.



7.1.3. Vessels

Vertical Vessels

The outside of skirts of vertical vessels located within an FPZ shall be

fireproofed if the vessel contains a total of more than 2 metric tonnes of

flammable product, the total mass (including contents) is more than 10 metric

tonnes, contains toxic material, or when failure may lead to consequences

beyond the property limit, including the environmental damage.

If there are flanges pipe connections within the circumference of the skirt,

fireproofing shall be applied to the inside of the skirt as well.

Horizontal Vessel and Exchangers

Saddles supporting horizontal vessels and exchangers shall not be fireproofed.

7.1.4. Structures Requiring Fireproofing Regardless of FPZ

General

Structures listed below shall be fireproofed irrespective of their location

relative to the FPZ.

Furnace Support Structures

Columns shall be fireproofed from grade level to the full height of the column.

All structural members incorporated to reduce the effective buckling length of

these columns shall be fireproofed. Main floor beams of furnaces shall be

fireproofed as well.

Supports of Pressurized Spheres and Bullets

Supporting legs shall be fireproofed in accordance with PGS-MD-003 Para.

11.5.

All columns and beams supporting bullets and structural members

incorporated to reduce the effective buckling length shall be fireproofed.

Storage Tank Pipe Bridges

At refrigerated and cryogenic storage tanks, the main frames of steel towers

which support pipes and/or pipe bridge shall be fireproofed.

Steel Pipe Supports Inside Storage Tank Bunded Areas

Steel pipe supports inside a storage tank bunded area shall be fully fireproofed

to the highest level of supported piping.



7.1.5. Cold Splash Protection

Cold splash protection shall be applied on steel members when there is a

danger of embrittlement of the steel due to the cooling effect of product

released from a PSL. If the steel structure is located in an FPZ, the

requirement for cold splash protection may already be satisfied by the required

fireproofing. If not, the fireproofing should give a minimum protection of 10 minutes to the effects of cold splash. If fireproofing is applied for the sole purpose of cold splash protection, it shall be limited to steel members

which support equipment weighing a minimum of 10 metric tonnes (including

contents). In the case, the fireproofing shall be applied within a radius of 3m from the PSL and down to HL.

The fireproofing system shall be able to withstand the atmospheric boiling

temperature of the product while the temperature of the steel structure should

not fall below its embrittlement temperature. A 50mm thick concrete cover

meets this requirement.

7.2. Buildings

7.2.1. All control buildings and substations which accommodate a control room, instrument auxiliary room and emergency control centre along with other

utility and electrical facilities fundamental to the control and shutdown of the

unit will require special consideration concerning resistance to fire radiation

and blast overpressures, in order to:

a) Maximise the safety of operations personnel working in the building.

b) Ensure that control of the plant is maintained during a major incident for sufficient time to permit a safe and orderly shutdown.

7.2.2. The final construction and location of the control buildings and substations shall depend on the results of fire radiation and explosion overpressure studies

during the preliminary hazard analyses. Physical separation will be provided,

but a minimum design blast design of 0.3 bar is to be used.

7.2.3. As a minimum the fire rating of a manned control building shall be two (2) hours for all external surfaces, including control room windows, doors and

penetrations. The internal walls and doors are to be one hour rated as

minimum, based on a celleslosic fire.



8. PROCESS SAFETY SYSTEMS

8.1. General

8.1.1. The requirement for over pressure protection shall follow onshore petrochemical practice, with due allowance being made for climatic

conditions. All vents and flare systems shall be designed in accordance with

API RP 520, Parts I and II, API RP 521 and PGS-ME-010.

8.1.2. All pressure vessels shall be protected against overpressure by Safety Relief Valves (Duty and Spare). A spare pressure safety relief valve (PSV) shall be

installed with suitable interlocking of the isolation block valves by castell key method so that more than one PSV cannot be taken out of service simultaneously.

8.1.3. Process safeguarding shall be developed based on the Emergency Shutdown Philosophy, the Flare System Design Basis and the EBDS system design.

(Refer to documents PGS-PU-111,11-PR-101-0004 and 11-PU-101-0002)

8.2. Emergency Shut Down (ESD) System

8.2.1. The ESD system shall be independent of the process control system. The ESD system shall be arranged to receive selected shutdown signals and generate

alarms to the other systems e.g. DCS for display of shutdown alarms.

8.2.2. It is proposed that there be three levels of shutdown.

Level 3: Total Plant Shutdown

Level 2: Unit Shutdown

Level 1: Local Shutdown

Each of the above shutdown levels, together with system blowdown, are

defined in Project Specification Emergency Shutdown and Isolation Philosophy document No. PGS-PU-111 and the relevant Emergency Shutdown Cause and Effect Charts. For details of shutdowns initiated by the fire and gas detection systems refer to the Fire and Gas Cause and Effect Charts.

8.2.3. An emergency shutdown shall protect individual pieces of equipment. Due consideration shall be given to the effect of shutdown of individual equipment

in relation to the overall safety of systems. The effect shall be to stop

individual equipment or a production train. An emergency shutdown will

normally leave process equipment at its operating pressure, in order to

facilitate production restart.



8.2.4. The following conditions shall be met in the design of the emergency shutdown systems:

a) Systems shall be designed so that they can be tested without interrupting operations;

b) Sensors included in safety systems shall be kept independent of, and in addition to, process control functions;

c) The critical high/low situations with regard to process parameters shall be monitored by dedicated instruments. These will be pressure or level

transmitters, etc.

d) When instrument sensors activate a protection function, the location shall be automatically signalled in the control room;

e) The control of each installations fire systems shall be exercised from one command point, located in the fire station, a safe and permanently manned

area. All pertinent information from production, fire and gas detection and

protection equipment, together with alarm and communications systems,

shall be monitored from this point.

The control of safety systems (e.g. blowdown) shall be exercised from the

Central Control Room

f) The ESD circuits and actuators shall be of the fail-safe type (normally energised devices, de-energise to trip);

g) ESD actuators and cables shall be protected and located with due consideration to the effects of fire or falling objects.

8.3. Emergency Shutdown Valves

All ESD valves shall be of a fire safe design as defined in Project Specification

Isolation/Shutdown Valves, with fireproofed actuators where fire risk analysis indicates this is necessary, rated as necessary, and be such that on actuation system

failure, the valve fails to the safe position. They shall be provided on bottom liquid

outlet lines from vessels containing 10m3 or more of flammable liquid (i.e. above its

flash point) and also on suction lines to pumps handling C4 or lighter material.

9. FIRE AND GAS DETECTION AND ALARM SYSTEMS

9.1. General

9.1.1. The purpose of the fire and gas detection system shall be to detect a fire or gas release, and initiate alarms and executive actions, where applicable, to

achieve maximum safeguarding of personnel, capital investment and the

environment.



9.1.2. Each building/unit shall be divided into uniquely numbered fire zones which are bounded by fire or blast-rated divisions, walls, roadways, piperacks and/or

determined by the extent of the fixed fire protection system.

9.1.3. Each area shall be evaluated from the results of the Hazard Assessment to determine the predominant risk and based on this, appropriate detection

devices, fire extinguishing and control measures shall be selected.

9.1.4. The selection of detectors, principle of operation, quantity and location shall consider the predominant combustible/flammable materials present, the type

of fire which may occur, and the possible presence of flammable/toxic gases,

together with the following:

a) The ambient conditions and likely causes of impaired performance.

b) Dispersion behaviour of smoke or gas and potential beneficial locations for fire and/or gas detectors, such as HVAC air intake ducts (for early warning

of possible smoke or gas ingress into enclosed areas) and identified areas

where there may be insufficient air changes.

c) Ventilation air flow patterns

d) Shielding by beams, equipment or piping

e) Possible failure modes, including risk of accidental damage, consequences of failure and the likelihood of false alarms.

f) Maintenance requirements including access, frequency and duration.

g) Performance requirements including performance standards and the speed of response to a developing hazard.

9.1.5. In addition, elements that can influence the effectiveness and efficiency of the detection and alarm systems are to be taken into consideration. This includes,

but is not limited to, the following:

Maximum and minimum temperatures

Wind direction and velocity

Obscuration by mists, dusts etc.

Presence of pollutants/inerts

Explosion hazards

Mechanical stress and vibrations

Noise levels

Electromagnetic influences

Mechanical damage

Plant obstructions



9.1.6. An addressable system employing addressable fire detectors and manual callpoints shall be considered for non-process buildings. Addressable systems

offer some advantages over conventional systems as signals from addressable

devices will be individually identified at the control point. They shall be

considered as an alternative to conventional detection systems as

recommended for process buildings and an appraisal will be undertaken at an

early stage during the detailed design phase.

The process area fire and gas detection field devices shall be wired into the

respective DCS and FGD system as discrete inputs and these devices shall be

non-addressable devices.

Gas detectors and other analogue devices which may be located in process

building ventilation ducting systems or in analyser shelters shall be wired to

the DCS. All fire detectors in the process buildings and their ventilation

ducting systems (including analyser shelters) shall be wired to the area FGD

system.

The fire detection devices for all process areas shall be brought into the FGD

system. The FGD system shall be located in the Satellite Instrument Shelters

(SISs) and shall have special marshalling cabinets dedicated to the process area fire detectors.

Reference shall be made to the Project Fire and Gas Specification 24168-

GGH-3PS-JQ05-00001.

9.1.7. The fire and gas control system functional logic for the individual fire zones within each unit will be identified on Fire and Gas Detection Cause and Effect Charts.

9.1.8. The alarm and shutdown philosophy actions shall be indicated on the Fire & Gas Cause and Effect Charts.

9.2. Fire Detection System

9.2.1. General

Based on the considerations for detector selection listed in section 9.1, each of

the unit areas and buildings shall be evaluated to provide the most suitable

type of detecting device and location based on the predominant fire risk and

the prime indication of a fire i.e. smoke, heat or flame and the extreme

environmental conditions.

The fire detection system shall be designed to:

Provide the earliest reliable detection of a fire

Alert personnel to the hazard

Initiate alarms in the respective Control Centres and the Fire Station

Initiate fire protection systems and fire pump start as applicable

Initiate preventive/control actions at an early stage to mitigate the consequences of a fire and prevent escalation



9.2.2. Types of Fire Detection Sensors

The type of fire detection sensors to be installed in the various units/areas of

the plant shall be selected from the following:

Frangible Bulb Heat Detectors

Multi-jet Controller (MJC)

Linear Heat Detection Cable

Rate Compensated, Fixed Temperature Heat Detectors

Rate of Temperature Rise Heat Detectors

Smoke Detectors Optical

Smoke Detectors Ionisation

Smoke Detectors Early Warning

Flame Detectors Infra-red (IR)

Flame Detectors Ultraviolet (UV)

Flame Detectors Combined UV/IR

Apart from the Frangible Bulb, MJC and Linear Heat detectors, all fire

detectors shall be of a type that can be reset, such that after activation they can

be restored to normal surveillance without the replacement of any

components.

9.2.3. Heat Detection Location Criteria

Heat detectors shall be installed in areas where flammable and combustible

materials are handled or stored, or where local normal operating conditions are

not considered suitable for installing the faster-acting flame and smoke

detectors, due to environmental factors.

Detectors shall be provided for all equipment where a release of

flammable/combustible fuel could occur, and hence potential for a fire. The

detectors shall be positioned adjacent to flanged connections, valves,

instrument connections, seals etc. Where a number of potential leakage points

are present, detector installation shall be based on general area coverage or

around the periphery of the risk area.

The temperature settings of the heat detectors shall be selected to suit

prevailing conditions. The alarm temperature shall generally be 30oC above

the maximum ambient temperature of the protected area.

9.2.3.1 Frangible Bulb Detectors

Frangible bulb heat detectors will only be used in the form of sprinkler heads

in fixed sprinkler systems protecting buildings containing ordinary

combustibles.



Operation of a frangible bulb sprinkler head will be detected and initiate

alarms by operation of the sprinkler system pressure switch.

9.2.3.2 Multi-jet Controllers (MJC)

Multi-jet Controllers complete with frangible bulb may be used in small

sprinkler systems where the installation of a sprinkler valve is not considered

necessary, or to control a group of open sprinkler heads within a

conventional sprinkler system.

9.2.3.3 Linear Heat Detection

Linear heat detection cable shall be installed in external fire risk areas

containing hydrocarbons or other flammable materials, primarily in

conjunction with waterspray systems and foam systems, for actuation of the

protection system. Typically, linear heat detection shall be located adjacent

to vessels and pumps, over the rim seal of floating roof tanks and on oil-

filled transformers.

Two linear heat detection cables, to allow for redundancy and routed in

parallel, shall be installed in the respective fire risk area.

9.2.3.4 Rate Compensated, Fixed Temperature Heat Detectors

Rate compensated, fixed temperature type heat detectors shall be installed

within buildings and enclosures.

Typically, point-type heat detectors shall be located in engine enclosures,

providing back up for flame detectors, and within kitchen areas where

sudden large changes in temperature are considered normal. The temperature

settings of the heat detectors shall be selected to suit the prevailing

conditions.

To allow for redundancy, the minimum number of detectors in any one fire

zone shall be two, wired on separate circuits (not required for addressable

detection systems). This will allow for single detector failure or fault. Due to

the high reliability of heat detectors, activation of a single detector shall

constitute a confirmed alarm.

9.2.3.5 Rate of Rise Heat Detectors

Rate of Rise type heat detectors shall be installed within workshops and

areas where smoke can be present during normal operations, e.g. welding

workshops, and thereby would preclude the use of smoke detectors. The

detectors shall incorporate a fixed temperature limit selected to suit the

prevailing conditions.

To allow for redundancy, the minimum number of detectors in any one fire

zone shall be two, wired on separate circuits (except where addressable

control systems are used). This will allow for single detector failure or fault.

Due to the high reliability of heat detectors, activation of a single detector

shall constitute a confirmed alarm.



9.2.3.6 Smoke Detection Location Criteria

Smoke detector selection shall be based on different principles of detection

and shall be either optical, ionisation or early warning type. Smoke detectors

shall be installed in enclosed areas, not in the open environment, where the

fuel source generates smouldering fires and where visible or invisible

products of combustion may be present. This includes Control Buildings,

Substations, SISs, HVAC Plant Rooms, electrical enclosures/voids, and

general administrative buildings.

In normally manned buildings, smoke detectors shall be installed to monitor the ventilation air inlet for ingress of smoke. This shall be achieved

by the use of aspirator cabinets which by their location will provide stable

sampling environment thereby providing fast response from the detector.

Siting of smoke detectors in buildings shall consider the room height,

mounting surface contours and obstructions. They shall also, where possible,

take account of stratification of the products of combustion during the early

stages of a fire and the effects of forced ventilation on flow patterns within

the protected area.

To allow a level of redundancy, a minimum of two detectors shall be

installed in any one fire zone, wired on separate circuits (except where

addressable control systems are used). Activation of two detectors shall

constitute a confirmed fire.

Smoke detectors for use within sub-station/control buildings shall be

mounted on ceilings and in the ventilation systems, and in voids if applicable

(inc. false ceilings, when more than 600mm deep).

High sensitivity smoke detection systems (VESDA) shall be installed in

control buildings, SISs and substations to protect electrical and electronic equipment that is critical for plant operation. The associated sampling

pipework shall be arranged to sample air from the area together with floor

and ceiling voids to provide early detection of the presence of low

concentrations of smoke.

9.2.4. Flame Detection Location Criteria

Flame detection selection shall be based on different principles of detection

and shall be either infra-red, ultraviolet or combined infra-red/ultraviolet.

Infra-red type flame detectors shall incorporate a 900 minimum field of view,

an optical test facility, a high immunity to false alarms and be resistant to solar

radiation, whether direct, reflected or modulating. They shall principally be

installed in semi-sheltered process areas containing or handling hydrocarbons,

or other flammable liquids or gas inventories. They shall also be considered

for selected non-process enclosures, such as diesel driven firewater pump

rooms.

EA



Ultraviolet type flame detectors shall incorporate a 900 minimum field of

view, an optical test facility and offer a high speed response. They shall be

employed in areas where they are considered the most suitable form of

detection e.g. turbine enclosures.

Combined infra-red/ultraviolet type flame detectors shall incorporate a 90o

minimum field of view, an optical test facility and be resistant to solar

radiation, whether direct, reflected or modulating. Simultaneous operation of

both the infra-red and ultraviolet channels will initiate an alarm. They shall be

considered as an alternative to infra-red detector applications as some

protection against spurious alarms is offered, and may be preferred by the

client.

In general, flame detectors shall be sited at the boundaries of selected fire

zones. They shall be directed inward and located at an elevation where they

have an effective field of view and positioned to minimise the possibility of

false alarms from detection of a flame in an adjacent fire zone or from the

flare stack. In locating flame detectors in congested areas, obscuration of the

field of vision shall be considered.

Where flame detectors initiate executive actions the detectors shall be

positioned such that the field of vision of one detector covers the field of

vision of the detector diametrically opposite.

To allow a level of redundancy, the minimum number of detectors in one fire

zone shall be two, wired on separate circuits. This will allow for single

detector failure, fault or obscuration. Activation of two detectors shall

constitute a confirmed fire, additionally a single detector in an alarm condition

and the other in fault, will constitute a confirmed fire.

9.2.5. Manual Alarm Callpoints

Manual alarm callpoints shall be strategically located throughout the unit areas

to provide alarm points in emergency situations and to supplement the

automatic fixed fire detection systems. The callpoints shall be coloured red, be

of the lift flap & push button type and grouped on a fire zone basis. They shall be positioned at the exits from buildings and adjacent to all escape routes

from both process and utility areas.

Once operated the callpoint shall remain in the alarm position until manually

reset, via key operation.

9.3. Gas Detection System

9.3.1. General

Each of the unit areas and buildings shall be evaluated to provide the most

suitable type of flammable gas detection where the accidental release or

subsequent ignition of such gas constitutes a possible threat to the installation

or personnel. The detector selection shall be based on the toxicity threshold in

comparison with the Lower Explosive Limit (LEL) of the predominant stream

components to provide the earliest detector response.

EA



Low level gas alarms shall be designed to:

Detect a release of flammable gas as early as possible.

Initiate alarms in the respective Control Centres

Confirmed high level gas alarms shall be designed to:

Initiate alarms in the respective Control Centres

Alert personnel of impending danger.

Shut down HVAC systems as applicable.

9.3.2. Flammable Gas Detection

Gas detectors shall primarily be installed to monitor areas of the plant where

flammable gas may escape and / or accumulate. Three types of gas detector

shall be considered, infra-red open path, infra-red point and electro-chemical

point. Each detector will respond to a level of accumulation and be designed to

alarm at two pre-set levels.

Infra-red point gas detectors shall be located in selected areas where essential

equipment is required to remain operational when a gas alert exists.

Equipment within these zones will remain energised until gas is detected in the

area.

Electro-chemical point detectors shall be located in rooms that contain nickel

cadmium batteries where, during a re-charge condition, high levels of

hydrogen may accumulate.

Output from individual detectors shall occur at set gas concentrations of 10%

Lower Explosive Limit (LEL) and 25% LEL, with the exception of ventilation

air intakes, where the alarm levels shall be 10% and 25%. Alarm levels for

hydrogen detectors in battery rooms shall also alarm at 10% and 25% LEL.

To allow a level of redundancy, the minimum number of detectors in any one

fire zone shall be two, wired on separate circuits. This will allow for a single

detector failure or fault. Due to the reliability of infra-red type gas detectors,

activation of a single detector shall initiate a confirmed gas alarm.

The exact location of detectors shall take into account:

leakage sources within the area

gas density relative to air

ventilation air flow patterns

system configuration

access for maintenance and calibration

EA

EA



9.4. Fire and Gas Detection Control

9.4.1. General

The FGD system shall provide for initiating output signals for control, alarm

and indication devices that shall function in a predetermined manner. These

shall include display devices such as remote annuciator panels, (synoptic or

mimic panels), personnel warning devices such as horns, lights, sirens, bells,

strobe lights, etc., and control outputs for HVAC, air movement, damper and

louvers, doors, elevator control, extinguishing system, inerting systems, fire

pump control and various equipment shutdowns.

The plantwide networked FGD system shall provide intelligent nodes to

integrate all individual plant systems on a plantwide network. Dedicated

Control room consoles will be installed to graphically display, control and

monitor all aspects of the individual plant FGD status and alarms.

9.4.2. Fire and Gas Panel Outputs

All outputs shall be normally open contacts with line monitoring. On detection

of a fire or gas release, outputs shall be provided for:

a) Visual and audible alarms in the Fire Station and Control Room and plant wide alarms to alert personnel

b) Automatically control HVAC fans and dampers to minimise risk to personnel

c) Alarm to the Fire Brigade

d) Initiate firewater pump start and actuation of the respective fire protection systems on confirmed fire detection

For details of the fire and gas inputs and outputs for the specific areas within

each unit see Fire and Gas Cause and Effect

9.4.3. Power Supplies

The power supply to the Fire & Gas Control System will be dual 240 V, 50 Hz

supplies. The fully redundant system power supplies shall be sized to support

the system in the event of complete failure of one Uninterruptible Power

Supply (UPS) and / or one system power supply.

A battery back-up and charger system shall therefore be installed to allow the

shutdown of the Fire & Gas control system in a controlled manner. The battery

back-up shall be sized to give 8 hours operation.



9.5. Fire and Gas Alarms

A confirmed fire or confirmed gas signal from fire or gas detection within the process

areas of each of the plants shall result in audible and visual alarms at the Fire Station

and Control Room.

Audible alarms initiated from a confirmed fire or confirmed gas signal shall also be

annunciated through the plant PA systems. A discreet confirmed Fire Alarm signal

and a discreet confirmed Gas Alarm shall be initiated from the Fire and Gas Panel and

passed to the PA systems, this will initiate plant wide alarm tones via the dual PA

speaker systems supplemented by flashing beacons located in areas of high ambient

noise.

Visible Alarms in Open Areas and Buildings

Red flashing light: fire

Blue flashing light: flammable gas

The main information/co-ordination center for the networked FGD will be the Fire

Station which shall be equipped with redundant fire system central servers, two 20

inch color SVGA monitors and a color large screen CRT display to present total

refinery networked FGD system information for control, alarming, indication, and

communication. Capability for history recording, event and alarm logging and status

and maintenance report writing shall also be provided at the Fire Station via

redundant servers. Extensive color graphic software packages shall be provided to

permit custom interactive graphic development and implementation by the

CONTRACTOR at the Fire Station CRTs.

The networked FGD system shall provide reliable, digitized solid stated circuitry with

the capability to record voice messages, to generator tones with precise control of

amplitude and frequency with amplifiers up to 100 watts. Complex wide speaker

zone control, annuciation and broadcast capability shall be provided. Pre-recorded

message splicing and menu capability for broadcasting capability shall be available.

Fire fighter two way telephone communication between master fire control panel and

remote fire fighter locations shall be provided within major buildings.

The FGD system shall be connected with the following systems:-

- Security System (access control)

- CCTV System

- Public Address System

The control signals of the FGD system shall cause the following actions:

A. Security System

The relevant doors shall be kept open to facilitate in and out access during emergency.



B. CCTV

- Connect the relevant cameras to predefined monitors

- Direct the camera to the affected location.

C. Public Address

Issuance of pre-recorded alarm messages (i.e. siren, speech, etc.) to the relevant zone

of to the whole plant.

10. ACTIVE FIRE PROTECTION

10.1. General

10.1.1. The level of fire protection required on the plant shall be determined by investigation of the fire hazards, the facilities design, the nature of the

equipment, the plant layout, and the plant manning.

10.1.2. Although adequate separation distances will be provided between individual items of equipment and between equipment areas, fire fighting and protection

facilities shall be installed to control or extinguish a potential fire and provide

exposure protection. Personnel, asset and environmental protection, and

continuity of production versus the consequences of a fire, requires a higher

level of protection by means of fixed active and passive fire protection and

portable fire fighting equipment.

10.1.3. The fixed fire protection system piping material shall be in accordance with project specification Piping Material Classes.

10.1.4. Equipment to be protected by fixed systems and equipment, and the distribution of manual fire fighting appliances, are defined in Data

sheets/schedules, to be issued as plant layouts are developed.

10.2. Fixed Fire Fighting Systems

10.2.1. Fire Water Supply

Firewater will be supplied from a freshwater storage tank at the unit. The total

water storage capacity shall be capable of supplying the firewater systems for

a minimum period of four hours at the maximum firewater demand, as

determined in accordance with Section 10.2.2 of this document. The water

supply to the firewater storage tank shall be capable of replenishing the total

capacity with seawater.

Firewater shall be delivered to the distribution system by at least 4 x 33%

pumps with identical duty. The duty firewater pump shall be electric motor

driven and the standby pumps diesel engine driven.

Duty and standby electric motor driven jockey pumps shall be installed to

maintain the pressure in the firewater ringmain at 2.0 bar g minimum/3.0 bar g

maximum with a minimum capacity of 15m3/hr.



In determining the firewater supply requirements, including pump capacity

and firewater ringmain diameter, the requirements for future the Polyethylene

Unit shall be taken into consideration. (1500 m3/hr)

The firewater storage tank capacity, the firewater pump demand and the

firewater ringmain diameter for each of the units shall be confirmed at the start

of detailed design of the fire systems.

A firewater distribution main shall provide firewater to each of the units/areas

requiring fixed fire fighting systems and equipment. The firewater ringmain

shall form a grid distribution system around the unit areas with sectional

isolation valves at maximum intervals of 300 m and at firewater ringmain

junctions. Branch connections shall be provided on the firewater ringmain for

extension of the main for future development of each unit.

Firewater ringmains shall be designed such that the maximum velocity in any

section of pipework does not exceed 3 m/s under normal operating conditions,

i.e. bi-directional flow.

The firewater ringmain will generally be buried to protect it from mechanical

damage. Where the main cannot be buried it shall be insulated and suitably

protected.

Isolation valves shall be provided on the firewater ring mains and on each of

the branches to fixed fire fighting equipment and systems, to permit sections

to be isolated for maintenance or repair without significantly impairing the fire

fighting capability of the installed systems. The isolation valves shall be

installed in valve pits and be operable from above grade by an extended

spindle with open/shut position indicator.

10.2.2. Fire Water System

The maximum firewater demand shall be based on the worst case fire scenario

as defined below:-

The quantity of water required for fire protection will be a based on 150% of the amount of water required to control and/or extinguish the worst credible

fire scenario. It shall include water for extinguishment and/or fire control,

exposure protection of adjacent tanks and/or equipment, utilising fixed fire

suppression systems, firewater monitors, hand held hoses and mobile fire

fighting equipment to cool tanks and/or equipment subject to a received

thermal radiation level of 8kW/m2 or greater. A total tank bund fire will be

considered for the double containment cryogenic ethylene tank. Consideration

for the application of firewater will be based on heat flux calculations from

credible process release rates, jet fires, product pooling and full can tank fires.

The initial sizing basis is a maximum demand of 1500m3/hr.



10.2.3. Waterspray Systems

Fixed automatic waterspray systems shall be installed for protection of the

following equipment:-

(Note that these figures will have an additional allowance of +10% and +20%

to allow for overspray, wind losses, etc..)

General Process Area

a) All pumps handling products at or above their auto-ignition temperature.

b) Pumps handling C4 and lighter products, including a perimeter width of 1.5m around the pump. The water rate shall be:

40 dm3/min/m2 directly over the pump

20 dm3/min/m2 over the area around the pump

c) Fire pump engines located in a pump house and cannot be covered by fixed water monitors. The water rate shall be:

40 dm3/min/m2 directly over diesel engine

20 dm3/min/m2 over the area around the engine

8.5 dm3/min/m2 over diesel fuel oil tank

d) All compressors handling C4 and lighter products at or above their auto-ignition temperature and cannot be covered by fixed water

monitors.

Water application rate shall be 40 dm3/min/m2 of ground service.

e) Vessels, columns and exchangers normally holding a liquid volume of C4 and lighter products of more than 5m3.

Water rate shall be 8.5 dm3/min/m2 of equipment surface.

Vertical vessels and columns shall be fully sprayed up to a minimum of 15m or 3m above the Hi-Hi liquid level of the vessel,

whichever is the greater. The vertical extent of the water spray

application shall be based on release scenarios and surface areas

that can sustain a pool fire.

f) For equipment installed in locations where a chimney effect will occur, water application rate shall be 20 l/min/m2 for adjacent equipment

surface.

Flammable liquid pumps will not be located under any elevated vessels

or equipment.



g) Automatically operated fog systems shall be installed for lube oil units, seal oil consoles, and gas compressor, etc., having an oil capacity of 1

m3 of more.

Water application rate shall be 8.5 dm3/min/m2 of equipment surface.

Storage Areas

Areas which shall be protected shall include the following:

a) Fixed roof storage tanks over 10m in height containing flammable products.

b) Floating roof storage tanks over 10m in height containing flammable products.

c) Pressure storage C4 and lighter hydrocarbons.

Fixed Roof Storage Tanks

a) Manually operated fixed water spraying systems shall be provided for exposure protection of roofs and walls from heat radiation from fire in

adjacent tanks and equipment. Spray systems shall be divided into two

sections for the ability to cool half the tank.

b) The minimum water application rate for tanks spaced in accordance with NFPA 30 is:

Tank roof: 1.7 dm3/min/m2 of surface area

Tank wall; 17 dm3/min/m2 of tank circumference (for the side potentially at risk)

Floating Roof Storage Tanks

a) Manually operated fixed water spraying systems shall be provided for exposure protection of walls from heat radiation from fire in adjacent

tanks and equipment. Spay systems shall be divided into two sections

to cool half the tank.

b) The minimum water application rate for tanks spaced in accordance with NFPA 30 is 17 dm

3/min/m

2 of tank circumference (for the side

potentially at risk).

Pressure Storage at C4 and Lighter Hydrocarbons

Spheres and vessels shall be protected against fires and radiation from the fires

of adjacent equipment by automatic water spray systems. Spray systems shall

ensure an even distribution of water over the entire surface of the sphere or

vessel regardless of wind forces or wind direction, but should be divided into



separate sections in order to limit water consumption when applying exposure

protection.

a) The minimum required water rate is 8.5 dm3/min/m2 of equipment for engulfed fires. Protection against heat radiation from adjacent

equipment will require much less water and shall be evaluated on the

basis of applicable distances.

Tanks with reinforcing rings on the shell shall be provided with additional

headers and nozzles for complete coverage.

10.2.4. Foam Systems and Equipment

Permanently installed low expansion foam systems shall be provided for areas

where significant volumes of flammable or combustible liquids are stored or

processed.

The foam injection facilities shall be installed local to the water spray system

control valves of the protected area(s) and be suitably protected but accessible

in an emergency. The foam storage shall be permanently connected either

locally at the valve set or at a central location to the firewater distribution

network supplying the individual water spray systems. The foam concentrate

shall be designed to mix with the firewater at a ratio of 6%.

Fixed foam pourer systems shall be provided for the protection of floating roof

storage tanks. The pourers shall discharge foam automatically onto the rim

seal between the foam dam and tank wall at a design application rate of

20 l/min/m2 of dam area.

The foam injection shall be electric motor driven pumped supply or through

inductors installed in the firewater supply line to the waterspray systems. In

selecting the type of foam injection system, consideration shall be given to

possible variations in the firewater supply flowrates for potential fire scenarios

and the pressure drop through the equipment. Foam shall be supplied

selectively as required on large zoned waterspray systems and automatically

on storage tank protection.

The stored volume of foam concentrate for fixed systems shall be sufficient to

operate the system for a minimum of 30 minutes and include 100% reserve

capacity. In addition, a reserve capacity of foam solution shall be provided for

replenishment of the foam trailers in each unit, this reserve shall be located at

the unit Fire Station or chemical stores.

The foam storage tanks and associated equipment and pipework shall be

suitably protected against mechanical damage and the environmental

conditions.

Firewater hydrants shall be installed throughout the process and hydrocarbon

storage areas with a maximum spacing of 50 metres between hydrants.

Hydrants shall also be provided at utility areas and adjacent to plant roads and

piperacks at a maximum distance of 2 metres from the kerb with a spacing of

80 metres between hydrants . Where possible the hydrants in the process and



utility areas shall be positioned such that they also serve the plant roads.

Hydrants in the process areas will be fitted with manually operated monitors.

Firewater hydrants shall be fed from a 6 diameter branch connection from the firewater ringmain and be four outlet, aboveground pillar-type of 6 nominal bore. The unit shall include 4 valved hose connectors of 65 mm nominal bore.

(Instantaneous Couplings) and 2 4 pumper connections (BS31 threads).

Fire hydrant dry risers shall be provide where vessels, drums or exchangers

etc. are installed on platforms elevated at 10 metres or greater above grade.

Fire hydrants / hose reel units shall be installed in warehouses, workshops,

firewater pump houses, fire stations, administration buildings and any other

buildings that contain significant quantities of ordinary combustibles. The

systems shall be designed in accordance with NFPA 101.

Suitable barriers shall be installed to protect the fire hydrants where they could

be subject to vehicle/mechanical damage. Where fire hydrants are installed

adjacent to plant roads a suitable hard standing for emergency response / fire

fighting vehicles shall be provided in the vicinity of the hydrant.

10.2.5. Firewater Monitors

Fire monitor nozzles shall have a minimum internal diameter of 28 mm. The

minimum operating pressure at the fire monitor nozzle shall be 6.0 bar.g,

dependant on discharge and throw requirements, and the reach/throw of the jet

spray shall be a minimum 30 metres. Where firewater monitors are to have

foam discharge capability, air aspirated type nozzles shall be used.

Fire monitors shall be capable of 360o rotation in the horizontal plane and +

75o to -15o in the vertical plane, be manually controlled or self oscillating

with locking facility/pre-set stops.

The branch from the firewater ringmain to fire monitors shall be minimum 6 diameter. An isolation valve shall be installed at the branch connection to the

firewater ringmain and a second valve at the fire monitor.

Fire monitors shall be located at a minimum distance of 15 metres from the

protected item. Where due to obstructions or space restrictions it is not

possible to meet this requirement, the distance may be reduced to not less than

10 metres with remotely operated monitors. The remote controls for the

monitor shall however be located a minimum distance of 15 metres from the

protected equipment.

To protect personnel operating a firewater monitor from thermal radiation, a

protective screen or water curtain shall be provided at each firewater monitor

station. The fire monitor supports shall be provided with passive protection

suitable for a minimum duration of 0.75 hours.



10.2.6. Gaseous Extinguishant Systems

Approved automatic gaseous extinguishant systems shall be installed in

Control Buildings and cable voids volume to protect electrical and electronic

equipment that is critical for plant operation or to maintain control in an

emergency. Gaseous Systems shall also be installed to protect substations,

UPS rooms, rack rooms, and associated underfloor areas.

All systems shall comprise of a 100% primary supply and a 100% reserve

supply (connected).

The gaseous systems shall have lock off facility to enable personnel to enter the protected building/enclosure.

Where gaseous extinguishing systems are installed, all entrance points to the

protected areas shall be provided with Status Lamps. The lamps shall consist

of three different coloured lenses, red, amber and green which shall indicate

the following extinguishant system status :

Red lamp Flashing, discharge imminent. Steady, system discharged.

Amber lamp Automatic system status.

Green lamp System locked off.

Each carbon dioxide protected area shall be provided with an audible alarm

system which shall annunciate a pulsed tone pre-discharge audible alarm and a

steady tone audible alarm which shall indicate system discharged.

10.3. Portable/Mobile Fire Fighting Equipment

Portable/mobile fire fighting equipment shall be provided in accordance with the

following:

a) Mobile ABC dry powder extinguishers - at locations where hydrocarbon spill fires can occur, e.g. condensate pumps.

b) Portable ABC dry powder extinguishers - at locations where process equipment contains hydrocarbon liquids or gases, small spill fires or general protection.

c) Portable CO2 extinguishers shall be located in areas with equipment which would otherwise be damaged or polluted by foam/dry powder, e.g. Substation / Control

Buildings.

Portable fire extinguishers shall be mounted at a height not exceeding 1.5 metres from

floor level to the bottom of the extinguisher and at a minimum distance of 1.2 metres

from the edge of door openings. Extinguishers shall be recessed into walls if located

along escape routes.

Mobile wheeled fire extinguishers shall be provided at the Fire Points in each process or storage area. The type of extinguishers shall be selected according to the materials

handled.



Gaseous extinguishers shall not be installed where they will be exposed to direct

sunlight or other heat sources.

10.4. Plant Fire Service

A Purpose-built fire station shall be provided by ABL. The contents of the fire station

in terms of facilities, equipment, quantity and capacity of fire fighting vehicles, water

/ foam vehicles, rescue equipment vehicle and emergency medic vehicles shall be

determined in consultation with the Regional Fire Inspectorate/Borouge. These items

are not supplied by ABL.

A monitor display providing information from the Fire and Gas System will be

provided in the fire station.

10.4.2. Where fixed fire-fighting systems have been provided, for identified high risk

process equipment and systems, these will provide the earliest response to any

developing fire, with automatic activation via the comprehensive fire detection

systems at each plant. The vehicles based at the affected site will then provide

next level of response to an emergency in the respective unit. Finally, should a

particularly serious incident occur, which is considered to exceed the

capabilities of the fixed and mobile systems at the affected site (not considered

to be likely), the vehicles from other units can provide additional support.

Thus, a multi-tier response shall be possible with the fixed and mobile systems

provided for each site in the development.

10.5. Painting

10.5.1. Fire extinguishing systems and equipment shall be painted in accordance with

international safety standards as necessary.

11. DRAINS SYSTEMS

11.1. General

11.1.1. Drain systems are required to:

a) Direct spills to a safe location where the spill can be retained and either recovered or disposed of;

b) Minimise the spread and area of exposure from spills and fires, for example, by providing retention bunds around storage vessels and

atmospheric tanks; and

c) Safely dispose of hydrocarbons during drain-down of process vessels and equipment, both during routine operations and during emergencies.

11.1.2. Hazardous and non-hazardous area drain systems shall be completely

segregated from each other so that there is no risk of contaminating non-

hazardous areas via backflow from a hazardous area.

11.1.3 No drain system shall be routed to a location which could affect the local

environment. All toxic or hazardous discharges must be treated to comply

with National Guidelines and Standards for Waste Management.



11.2. Surface Water Drains

Roads and paved areas shall be sloped to low points at the pavement edge or road

shoulder. Underground rain water drainage systems shall be provided to cater for the

expected conditions. Underground systems shall be submerged or flooded.

11.3. Process Drains

11.3.1 Process drains from vessels, equipment, instrumentation and piping shall be

via dedicated closed drain headers to a closed vessel or closed sump. The

closed vessel will be either the flare KO drum or a slop tank.

12. ELECTRICAL SAFETY

12.1. General

The electrical design shall provide the following:

Safety to personnel and equipment;

Reliability of service;

Minimum fire risk by minimisation of likelihood of ignition of leaks and inherent safety.

12.2. Applicable Codes and Standards

Electrical installations on process units must normally comply with the requirements

of IEC (International Electrotechnical Committee) standards throughout, although

hazardous area classification will follow the guidelines of the Institute of Petroleum

Model Code of Safe Practice Part 15 Area Classification Code for Petroleum Installations (IP 15).

Reference should be made to the Electrical Design Guidelines, PGS-EU-001, for

general safe features of Electrical Design and Installation.

12.3. Safety Review

A safety/operability review of the various electrical systems shall be performed

during detailed design.

13. HVAC SYSTEMS

13.1. General

Ventilation requirements can be split into two distinct groups:

a) Ventilation of safe areas, where smoke and gas hazards exist outside the building and the design intent is to maintain breathable atmosphere within; and



b) Ventilation of enclosed process areas (for example, some pumps and gas compressors), where the potential for accumulation of flammable or toxic gases

exists due to possible leaks from the process equipment, and where the design

intent is to ensure that:

i) during routine operations, fugitive emissions are well diluted, so that they do not present an accumulation hazard; and

ii) during emergencies, following a leak within the enclosure/building, the concentration of the hazardous material is diluted below flammable or toxic

levels.

Ventilation is an input parameter to hazardous area classification exercises, as

indicated in Section 5.

13.2. Safe Area Ventilation

13.2.1 HVAC systems for the substations and control buildings shall be designed

with due consideration for area classification, equipment location, fire

integrity, smoke and gas ingress and personnel requirements.

13.2.2 The following rooms and enclosures shall be provided with suitable HVAC or

mechanical ventilation systems as required by codes:

Control Rooms

Transformer Rooms

Switchgear Rooms

Battery Rooms

HVAC Rooms

Firewater Pump Rooms

SISs

Fire Station

Air intake stacks for these HVAC systems shall be located outside any hazard

envelope defined on the electrical area classification drawings.

13.2.3. Upon loss of electrical power, the HVAC fire dampers of the substations and

control buildings shall close and the fans shall trip.

13.3. Ventilation of Enclosed Process Areas (Typically Analyser Houses)

13.3.1. It is possible that some process equipment will be located in mechanically

ventilated buildings, which presents a gas accumulation hazard, both through

fugitive emissions and accidental leaks. The mechanical ventilation systems

are intended to counteract these hazards.



13.3.2. The minimum air exchange rates to be applied during normal operation are detailed in IP Pt. 15 (Normally 12 per hour). Emergency Ventilation start-up

shall be automatic on detection of flammable gas concentrations above

20% LEL in the protected enclosure.

14. FLARES AND VENTS

14.1. General

The Project shall have separate flare systems for the Ethylene Unit and Polyethylene

Units. Flare headers shall run on the common piperack to dedicated flare KO systems

and flare risers and tips. The risers and tips shall be supported in a flare stack

structure. PE and EU unit flares shall be accommodated in a common structure, flare

tips being spaced so as to cater adequately for the effects of radiation and wind

velocity on flare tips not in operation. The sterile areas shall be sized to allow for

simultaneous operation of all three flares, and will be based on levels stated in API RP

521, with due allowance for solar radiation. The limit of radiation at the edge of the

sterile area will be 1.58 kW/M2.

All hydrocarbon reliefs shall be routed to the flare. The design is to provide

alternative routings for tank farm boil off and relief valves in a main plant shutdown

period. (typically, once every 4 years).

In principle there shall be no flaring of hydrocarbon streams during normal operation.

14.2. Ethylene Unit Reliefs

Within the Ethylene Unit provision shall be made to segregate hot and cold relief and

blowdown.

Dry and cold releases within the Ethylene Unit and storage area shall be collected in a

dry flare header and routed to a dry flare/blowdown drum. Dry and cold liquid drains

from these areas shall be collected in the separate dry blowdown header and routed to

the same drum. Liquid that accumulates shall be vaporised. The vapour outlet from

this drum passes to the main flare header.

Wet or warm (above 0C) releases within the EU shall be collected in a wet flare header and passed to a wet flare/blowdown drum. Warm or wet liquid drains shall be

collected in the separate wet blowdown header and also passed to this drum. Liquid

shall be passed from this drum to the slop tank. Vapour from the drum joins the main

flare header.

For further information refer to Flare System Concept Document No. 11-PR-101-

0004.

15. HAZARDOUS MATERIALS

15.1. General

A hazardous material inventory shall be maintained for each installation. This shall

include all flammable materials, corrosive and toxic substances, and any radioactive

materials which are to be stored permanently or temporarily at the installations.



Recommendations for the storage of materials identified in the hazardous material

inventory shall be made according to their nature. Paints and flammable materials

shall be stored as far as is practicable away from other hazardous areas. Corrosive or

toxic chemicals shall be stored in suitable containers marked with warnings and

precautionary measures.

Personnel involved in handling, decanting or moving hazardous material must be fully

trained and competent to do so. Detailed procedures, protective clothing, respiratory

equipment etc. shall be provided for those personnel.

16. NOISE AND VIBRATION

16.1. General

Noise levels shall be limited throughout the installation to:

Minimise the risk of hearing damage to personnel

Ensure alarms are audible

Permit adequate speech, telephone and radio communication

Maintain working efficiency

Similarly vibration levels shall be limited, in order to:

Prevent a health hazard

Maintain proficiency of personnel performing designated tasks.

The need for noise and vibration control shall be evaluated during detailed design.

The maximum acceptable noise levels and method of protection are defined in project

specification Document No. PGS-MU-009 Equipment Noise Control.

16.2. Noise Control

16.2.1. Noise limits for individual items of machinery shall be specified taking into

account the results of a project noise study, and the location of equipment and

its