Operational Integrity Testing of Fixed Firefighting … · Web viewDocument Title: Operational Integrity Testing of Fixed Firefighting Systems Document ID PR-1147 Document Type Procedure

Petroleum Development Oman L.L.C.

Document Title: Operational Integrity Testing of Fixed Firefighting Systems

Document ID PR-1147

Document Type Procedure

Security Unrestricted

Discipline Engineering and Operations

Owner UOP – Functional Production Manager

Issue Date August 2011

Revision 3.0

Petroleum Development Oman LLC Revision: 3.0Effective: Aug-11

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Page 2 PR-1147 - Operational Integrity Testing of Fixed Firefighting Systems

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The controlled version of this CMF Document resides online in Livelink®. Printed copies are UNCONTROLLED.

This document is the property of Petroleum Development Oman, LLC. Neither the whole nor any part of this document may be disclosed to others or reproduced, stored in a retrieval system, or transmitted in any form by any means (electronic, mechanical, reprographic recording or otherwise) without prior written consent of the owner.


i Document AuthorisationAuthorised For Issue – August 2011


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ii Revision HistoryThe following is a brief summary of the 4 most recent revisions to this document. Details of all revisions prior to these are held on file by the issuing department.

Revision No. Date Author Scope / Remarks

3.0 Aug-11 Robin Norman UOP6 Reviewed and Revalidated

2.0 Dec-07 Robin Norman UOP6 Reformat, Review and RevisionTitle amended.

Sep-01 UOP1 Reviewed and Revalidated

1.0 Oct-98 UOP1 New Procedure.

iii Related Business Processes

Code Business Process (EPBM 4.0)EP.71.02 Operate Wells and Facilities

iv Related Corporate Management Frame Work (CMF) Documents

The related CMF Documents can be retrieved from the CMF Business Control Portal.

Refer to Appendix 2


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TABLE OF CONTENTS

1 Introduction....................................................................................................................... 6

1.2 Purpose....................................................................................................................... 6

1.3 Distribution / Target Audience......................................................................................6

1.4 Changes to the Document............................................................................................6

1.5 Step-out Approval........................................................................................................6

2 Roles and Responsibilities.................................................................................................7

3 Operations Integrity Testing of Fixed Firefighting Systems Procedures..............................8

3.1 Scope.......................................................................................................................... 8

3.2 Permit to Work and Safety System Overrides...............................................................8

3.3 Firewater Ring Mains and Firewater Pumps.................................................................8

3.4 Firewater Deluge Systems.........................................................................................10

3.5 Foam Systems...........................................................................................................12

3.6 Sprinkler Systems......................................................................................................15

3.7 Fire Suppressant Delivery Systems............................................................................16

4 Testing, Maintenance and Fault / Defect Reporting..........................................................18

4.1 Operational Testing....................................................................................................18

4.2 1st Line Maintenance..................................................................................................18

4.3 Fault / Defect Reporting.............................................................................................19

Appendix 1 – Abbreviations....................................................................................................20

Appendix 2 – Reference Material............................................................................................21

Appendix 3 - User Feedback Page.........................................................................................22

Addendum – Changes to the Document at Revision 3.0..........................................................23


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1 Introduction1.1 Background

Fixed Firefighting systems are provided at the majority of facilities in the North, South Gas Directorates to provide the capability to fight major hydrocarbon fires. The systems are fully automatic or require some manual intervention to be activated. It is the responsibility of all personnel on the sites to ensure that these systems are maintained and tested regularly so that they are always available.

Typically sites shall be provided with one or more (dependant on type of operation) of the following:

Fixed firewater system comprising of dedicated pumps, ring main and hydrants

Fixed water deluge system (selected vessels and areas)

Foam delivery systems (including tank injection)

Sprinkler systems for offices, warehouses, stores etc.

Fire suppressant delivery system for containerised equipment such as switchgear, compressors, generators etc.

Regular periodic testing of the systems shall be undertaken by Operations personnel at the site and any defects or irregularities recorded in the station log and reported to Production Coordinator for action and rectification.

1.2 PurposeThis procedure details at high level the requirements for testing and 1st line maintenance for all fixed firefighting systems located at the various locations in PDO. Where required more detailed procedures shall be provided specific to the location.

1.3 Distribution / Target AudienceThis procedure shall be referenced by all Operations and Maintenance personnel in connection with integrity testing of fixed firefighting equipment.

1.4 Changes to the DocumentResponsibility for the upkeep of the Document shall be with the Functional Production Manager (UOP), the Owner. Changes to this document shall be authorised by the Owner.

Users of the Document who identify inaccuracy or ambiguity can notify the Custodian or his / her delegate and request changes be initiated. The Requests shall be forwarded to the Custodian using the ‘User Feedback Page’ provided in this Document.

The Document Custodian on behalf of the Document Owner shall ensure review and re-verification of this procedure every 3 years.

1.5 Step-out ApprovalThis procedure is mandatory and shall be complied with at all times. Should compliance with the procedure be considered inappropriate or the intended activity cannot be effectively completed or safely performed, then step out authorisation and approval must be obtained in accordance with PR-1001e – Operations Procedure Temporary Variance, prior to any changes or activities associated with the procedure being carried out.


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2 Roles and Responsibilities

Production Coordinator

Responsible for ensuring that Fixed Firefighting Systems are tested and maintained in accordance with this procedure

Audits reports and records of inspections and tests

Production Supervisor

Responsible for overseeing the Fixed Firefighting System test

Witnessing and verifying test results

Production Operator

Undertaking Fixed Firefighting System testing in accordance with this procedure and local specific procedures

Undertaking 1st Line Maintenance in accordance with this procedure or maintenance schedules

Raise Z1 Notification when faults or defects are identified

Maintenance Technician

Assisting and performing 1st Line and Corrective maintenance in accordance with this procedure or maintenance schedules

Raise Z1 Notification when faults or defects are identified


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3 Operations Integrity Testing of Fixed Firefighting Systems Procedures

3.1 ScopeThe procedure covers Fixed Firefighting Systems irrespective of the location. The level has been kept suitably high level so that the procedures can be applicable to all or most location within PDO.

Fixed Firefighting Systems are defined as stated in Section 1.1 of the procedure but can be generally assumed to be fixtures that are not easily moveable.

Included where applicable in each procedure shall be references to maintenance tasks that can be undertaken by operations personnel with any specialist training. Reference should be made to PR-1100 - Operator Routine Functions for more details on this subject.

3.2 Permit to Work and Safety System Overrides

3.2.1 Permit to Work (PTW)PTW certificate may be required during integrity testing of fixed firefighting systems dependant on the type of testing being undertaken.

For example:

A PTW will not be required for; testing of the jockey pump for ‘auto’ start by relieving pressure in the firewater system and monitoring auto start / stop pressure; or testing the ‘auto’ start of the firewater pump while set to automatic mode; provided the work is carried out by operations.

A PTW will be required when performance testing the firewater pump; dry testing a deluge system with firewater supply isolated; or checking the condition of the frangible bulbs on a sprinkler head.

3.2.2 Temporary Overrides on Fixed Firefighting SystemsIntegrity testing of fixed firefighting systems may require that automatic detection and initiation systems to be overridden for the duration of the work. Overriding will be carried out in accordance with PR-1001c - Temporary Overriding of Safeguarding Systems and under the PTW system.

The use of overrides must be recorded in the Station Override Log when applied and removed. Overrides will only be applied by authorised personnel under strict control and remain in place while the station is manned.

3.3 Firewater Ring Mains and Firewater Pumps

3.3.1 GeneralFirewater ring main systems will be provided on most sites where continuous fire protection is required. Generally the systems are supplied from a dedicated water supply and are maintained pressurised via a jockey pumps.


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Larger diesel driven or electrically driven firewater pump(s) shall be provided for the delivery of firewater to the system ring main should an emergency occurs that requires large volumes of water to be supplied under pressure. The firewater pump(s) are automatically started on initiation of a confirmed fire signal from the F&G Logic or low pressure in the ring main caused by opening of fire hydrants.

3.3.2 Operational Integrity Testing

1. Check the operation of the jockey (pressurising) pump. Ensure the pump operates between the high and low pressure settings to maintain firewater ring main pressure.

2. Inspect firewater ring main above ground for signs of corrosion or damage.

3. Inspect firewater hydrants for damage and corrosion. Ensure that the seals are in good condition and that covers are fitted to prevent the ingress of sand.

Lightly grease the rubber seals to maintain flexibility.

4. Check the operation of all fire fighting monitors1. Lubricate and grease where required.

1 Automatic oscillating fire monitors should have a maintenance routine applied in addition to that required by this procedure.Page 9 PR-1147 - Operational Integrity Testing of Fixed

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5. Check operation of main isolation and X-connection valves. Ensure valves are not seized or stiff. Grease spindles and gearing where applicable.

6. Select the TEST mode at the Firewater Pump Panel2.

7. Initiate a start of the Firewater Pump(s) by any of the automatic start parameters such as:

Low firewater ring main pressure

MAC

Remote firewater pump start location

Remotely from the F&G Panel in the CCR

8. Check operation of the minimum flow loop

9. Check firewater ring main and hydrants for leaks. Ensure that there are no excessive leaks on the valves gland.

Record pressure and flow and record.

10. Stop Firewater Pump(s) and return system logic to normal standby position.

11. Sign off test, record readings if required and report all defective equipment / leaks.

3.4 Firewater Deluge Systems

3.4.1 GeneralGenerally deluge systems are provided to protect vessels and tanks from radiant heat caused by surrounding fires. Firewater is distributed across the protected area using nozzles which are fixed to provide a drenching pattern. Normally the systems are maintained dry and firewater is allowed to enter the system by the operation of a ‘clack valve’. The clack valve can be operated from fusible loops or from the F&G logic.

On installations where a fixed firewater system is not available then the deluge systems may be supplied from dedicated pressurised water tanks. The duration of the system is then limited to the amount of water stored in the tank and the availability of back-up supplies.

3.4.2 Operational Integrity Testing1. Is the Operational Integrity Test to be performed using a ‘wet’ or ‘dry’ system?

i.e. is water to be allowed through a normally dry system. If the test is to be ‘dry’ reference steps 2 through 5 below. For a ‘wet’ test proceed to step 6.

2. Apply the required ‘Maintenance Overrides’ or ‘Defeats’ on the system to prevent the introduction of firewater / water to the system discharge pipework.

3. Isolate the main firewater / water isolation valve (upstream of the clack valve).

4. Activate the Deluge release for the respective area under test from the fusible loop, local release point or F&G logic. Ensure that all alarm and indication is activated and is in the correct sequence.

NOTE: The Overrides will prevent executive actions such as firewater pump start and SDV shut in from occurring if these are part of the operation logic for

2 The Firewater Pump Panel is set to TEST to protect the pump during the test running. Normal logic is for the all safety shutdowns are overridden in a fire situation. The pump will run to destruct. “Stressed engine condition” safeguards are not permitted on firewater pumps e.g. cooling water monitoring, etc.Page 10 PR-1147 - Operational Integrity Testing of Fixed




the system.

5. On successful completion of the test reset the system and remove the Overrides. Ensure firewater / water isolation is open.

6. Inspect the area where the test is to initiated and ensure that exposed equipment such as motors and control panels are protected from water ingress.

7. Before initiating a ‘wet’ test all personnel in the area shall be informed that a


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test is about to take place.

8. Activate the respective deluge system from the local or remote release points. The release may be from the fusible loop, local release point of via the F&G logic.

9. Check that all executive actions (unless overridden) and alarms and indication are correct.

NOTE: Executive actions associated with a deluge release can include remote starting of the firewater pump(s) and a station ESD. If any associated action is not required then the appropriate override shall be put in place.

Check deluge supply pressure are correct for the system.

Check the distribution of the deluge and that all nozzles are operating correctly. Record any defects.

10. On successful completion of the test reset the system and remove any overrides which have been set.

If the system pipework is normally dry it should be blown through with dry air to remove any free water.

11. Sign off test, record readings and report all defective equipment / leaks.

3.5 Foam Systems

3.5.1 GeneralFoam systems are provided where free surface liquid fires could occur or as a means of suppressing fires in the roof space floating roof storage tanks.

Foam can be generated through foam monitors or from dedicated foam generation skids (as used for MAF storage tanks). The chemical foam compound is induced into the firewater stream through an inductor and is mixed to produce foam at the nozzle or the injection point.

Foam is stored either in containers alongside the monitor with the inductor hose connected to the monitor and the tank or in the case of larger fixed systems in a foam concentrate tank attached to the inductors of the skid.

Initiations of the monitors are normally manual and for the fixed skid installations from a fusible plug loop and automatic clack valve.

3.5.2 Operational Integrity Testing1. Is the Operational Integrity Test to be performed using a Foam release?

If a foam release is to be used then a decision shall be made by the Production Supervisor as to whether the release shall to the protected area or not. It may be advisable for operational reasons to direct the foam to a vacant area in which case if provision in the pipework (fixed system) is not made a temporary break in the pipework may be required.

If the test is to be ‘without foam’ reference steps 2 through 6 below. For a ‘foam’ test proceed to step 7.

2. Apply the required ‘Maintenance Overrides’ or ‘Defeats’ on the system to prevent the unplanned shutdowns.


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3. Isolate the foam concentrate supply and ensure the foam concentrate supply pump if provided is electrically isolated or set to Local to prevent starting.

4. Activate the Foam System for the respective area under test from the fusible loop, local release point or F&G logic.

Ensure that all alarm and indication is activated and is in the correct sequence.

NOTE: The Overrides will prevent executive actions such as ESD and / or SDV shut in from occurring if these are part of the operation logic for the system.

5. On successful completion of the test reset the system and remove the Page 13 PR-1147 - Operational Integrity Testing of Fixed




Overrides. Ensure foam concentrate isolation valves are Opened and the foam concentrate supply pump is electrically de-isolated or rest to AUTO.

6. Take samples of the foam concentrate for analysis.

7. Before the test

Check that sufficient Foam Concentrate is available in the storage tanks / containers.

Check for leaks on tank / container pipework.

Check all foam concentrate isolation valves are Open.

Check the foam concentrate supply pump is set to AUTO and is electrically energised.


The use of foam can cause deposits to be left on piping and structures in the protected area. This should be washed down with services water on completion of the tests.

To address the above when testing foam monitors the direction of the nozzle can be adjusted temporarily and the foam blanket direct to a clear area away from the vessel, tank or protected area. Consideration should be given here to the effectiveness of the blanket and delivery pattern. If the foam is for the protection of a storage tank then consideration may be given to a temporary break in the delivery pipework while the test is being undertaken. This must only be done with permission from the Production Coordinator and assurances that the integrity of the protection shall not be compromised by undertaking this action.

NOTE: If foam monitors are moved for the purpose of the test then they must be returned to their original position on completion to ensure they are ready in the case of an emergency.

9. Activate the Foam System for the respective area under test from the fusible loop, local release point or F&G logic.

Ensure that all alarm and indication is activated and is in the correct sequence.

NOTE: The Overrides will prevent executive actions such as ESD and / or SDV shut in from occurring if these are part of the operation logic for the system.

10. Check correct operation of the delivery devices i.e. foam monitors and foam generation skids. Ensure that the consistency of the foam is sufficient to be able to produce the required blanket and that the pattern provides sufficient cover.

Check that all associated executive actions occur and alarms and indications are all correct.

11. On completion of the test(s) isolate the foam supplies and flush through the delivery pipework to remove all foam deposits. Run through with water until the discharges are clear.

Reset the system and ensure all foam valves are open and that stocks of foam concentrate have been replenished.

12. Sign off test, record readings if required and report all defective equipment / leaks.


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3.6 Sprinkler Systems

3.6.1 GeneralSprinkler Systems are normally provided in enclosed spaces where carbonaceous fires are a hazard, such as stores, offices and accommodation area. Sprinkler systems provide wide area automatic protection and can be initiated by frangible bulbs, heat and smoke detectors and manually.

The systems normally comprises of a pressurised storage tank, a ‘clack valve’ and a ring main of sprinkler heads. The ring main is normally maintained dry, with the exception of systems provided with frangible bulbs which may be charged with water. For systems using a ‘clack valve’ the valve may be held in the Closed position by pneumatic pressure. Release of the pressure will allow the valve to open and release the pressurised water from the storage into the sprinkler system to contain or extinguish the fire.

Testing of sprinkler systems is normally carried out ‘dry’ and is to ensure that all alarms and indication are operating correctly.

3.6.2 Operational Integrity Testing


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Sprinkler systems may be linked through the F&G logic to the firewater pump(s) and ventilation / AC systems causing the systems to activate / deactivate when the sprinkler is initiated.

2. Before testing the system a thorough check should be carried out.

Ensure that all the sprinkler ‘roses’ are in place and not damaged.

Inspect the system for signs of water leakage past the ‘clack valve’

Check the condition of the ‘clack valve’ and control supplies to the valve

3. Isolate the water supply to the sprinkler system upstream of the ‘clack valve’.

4. Activate the sprinkler system from a local or remote position.

NOTE: Sprinkler systems are activated via smoke and heat detection which would require activation to be from the local ‘test’ position.

5. Check correct operation of the system. Check that alarm and indication is activated and any executive actions that are associated with the system.

6. On completion of the test(s) reset the system to normal.

Check the ‘clack valve’ is Closed before opening the isolation on the water supply.

Recheck the pressure on the water pressure vessel.

Inspect around sprinkler ‘roses’ for signs of leaking.

7. Sign off test, record readings report all defective equipment / leaks.

3.7 Fire Suppressant Delivery Systems

3.7.1 GeneralThe most commonly used Fire Suppressant Delivery system are CO2 and Halon3. The systems are commonly found on gas turbine, power generation, switchgear and compressor enclosures which are under normal operating conditions unmanned.

The suppressant is stored in cylinders which are located outside of the protected area and then piped in and released via strategically located nozzles in to the enclosure.

The suppressant is used to deprive the fire of oxygen by reducing the content and as little cooling effect. Entry into the enclosure under normal operating conditions, when the suppressant is ‘armed’ is prohibited. All other entries are by Permit to Work and the suppressant system must be ‘disarmed’. The systems are not tested live i.e. a suppressant release, all test are carried out as ‘dry runs’ and the release system is locked out.

Reference should be made to the Vendors literature and test procedures before carrying out operational integrity tests.

3 The use of Halon 1211 & 1301 as a Fire Suppressant is now being phased out because it is depletes the ozone layer if released.Page 16 PR-1147 - Operational Integrity Testing of Fixed




3.7.2 Operational Integrity Testing1. Carryout visual inspection of the fire suppressant system and check:

Security of suppressant cylinder racks

Main cylinder and pilot cylinder pressures

‘Locked Open’ and ‘Locked Closed’ valves at correct status

System ‘armed’ and all indication at ‘Normal / Operational’ status (refer to Vendors O&M Manual)

No signs of physical damage on delivery system pipework.

2. In accordance with the Vendor recommended practices perform necessary functions tests on the system. Ensure alarm and indication is activated at the Local and Remote locations.

Ensure the systems are reset on completion of all tests.

Fire Suppressant Delivery System should be inspected by the Vendor or a 3 rd Party Specialist Company every 12 months and the system actuated without an extinguishant release (suppressant isolated). The test should ensure that all executive actions associated with the system are functional.

Faults identified on the system shall be rectified immediately or the protected equipment removed from service until the faults have been rectified.


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4 Testing, Maintenance and Fault / Defect Reporting

4.1 Operational Testing

The following frequencies are recommended for Operational Integrity Testing of Fixed Firefighting Systems.

Fixed Firefighting System

Frequency Test

Firewater System Weekly Test Run Firewater Pump(s) Operation of hydrants Operation of fire monitors Alarms and Indication

Deluge System Monthly Alarms and Indication Pattern of spray (wet test) Coverage (wet test)

Foam System Monthly Alarms and Indication Operation of system (no foam) Operation of system (with foam) Foam density and coverage

Six Monthly Analysis of foam concentrateSprinkler System Monthly Alarms and Indication

Operation of system (dry test)Fire Suppressant Delivery System

Monthly Alarms and Indication Operation of system (dry test)

Yearly Operation test and inspection (Vendor or 3rd Party Inspector)

4.2 1st Line Maintenance

1st Line Maintenance is the servicing that can be carried out by Operations Personnel at the time of inspection and testing of the fixed firefighting system. The following are recommendations and should only be considered if a detailed ‘campaign maintenance’ schedule is not in place.

4.2.1 Firewater SystemsCheck for signs of damage to the systemCheck for leaking hydrants and passing valves. Tighten glands.Check firewater monitors and ensure that the elevations of fixed monitors are

correct. Grease locking handles if required.Check the gearbox oil levels on firewater oscillating monitors and grease / lubricate

training gear as required.


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Inspect firewater pump(s). For diesel driven check that engine oil, cooling water and fuel header tanks are the correct levels. Replenish or report. Visually inspect conditions of engine belts and ensure all guards are secure and in place.

If hoses are connected to hydrants check and report the condition of the hoses.

4.2.2 Deluge Systems Check for signs of damage to the system pipework Check for blocked or leaking nozzles Inspect ‘clack valve’ assembly and check for leaks on pneumatic lines (if

provided)

4.2.3 Foam SystemsCheck the system for signs of leakage especially around foam storage tanks and

containersCheck foam levels and replenish as required4

Inspect and lubricate foam monitor locking and training gearCheck for leaking and passing system valves. Tighten glandsCheck foam diffusers where provided and ensure that they are not damaged or

distorted

4.2.4 Sprinkler Systems Inspect pressurised water storage vessel for leaks. Ensure charge pressure is

correct Check system pipe work for leaks Inspect sprinkler heads for damage. If system is fitted with frangible bulbs

check for damage or leaks at seat

4.2.5 Fire Suppressant Delivery SystemsRefer to the Vendors O&M manual for requirements of 1st Line Maintenance.

4.3 Fault / Defect ReportingFaults and defects that are found during normal site inspections, testing or during maintenance shall be reported by raising a Z1 Notification.

The notification shall be included in the Daily Notification Meeting and prioritised. The process of work preparation, scheduling and execution shall be in accordance with established maintenance procedures and in accordance with CP-114 Maintenance and Integrity Management Code of Practice.

4 When handling foam concentrate adhere to the requirements of the SHOC cardPage 19 PR-1147 - Operational Integrity Testing of Fixed






Appendix 1 – Abbreviations

F&G Fire and Gas

MAC Manual Alarm Call Point

CCR Central Control Room

ESD Emergency Shut Down

SDV Shut Down Valve

O&M Operations and Maintenance


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Appendix 2 – Reference Material

CP-114 Maintenance and Integrity Management Code of Practice

PR-1001c - Temporary Overriding of Safeguarding Systems

PR-1001e – Operations Procedure Temporary Variance

PR-1100 - Operator Routine Functions

PR-1172 - Permit to Work System Manual


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Appendix 3 - User Feedback Page

PR-1147 – Operational Integrity Testing of Fixed Firefighting Systems User Feedback Page

Any user who identifies an inaccuracy, error or ambiguity is requested to notify the custodian so that appropriate action can be taken. The user is requested to return this page fully completed, indicating precisely the amendment(s) recommended.

Name:

Ref ID Date:

Page Ref: Brief Description of Change Required and Reasons

UOP7 - PTW System Coordinator

Custodian of Document Date:


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Addendum – Changes to the Document at Revision 3.0

1. Layout changed to comply with latest format

2. Testing, Maintenance and Fault / Defect Reporting incorporated into a new Section 4

3. Operations personnel and maintenance technicians given responsibility to raise Z1 Notification for failures, defects found on systems

4. Section 3.2 clarified on PTW requirements for working on Fixed Firefighting Systems

5. New Section 4.3 Fault / Defect reporting added


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