FM Global Property Loss Prevention Data Sheets

7-14
July 1997 Revised May 2004 Page 1 of 9

FIRE & EXPLOSION PROTECTION FOR FLAMMABLE LIQUID, FLAMMABLE GAS, & LIQUEFIED FLAMMABLE GAS PROCESSING EQUIPMENT & SUPPORTING STRUCTURES

Table of Contents
Page 1.0 SCOPE ................................................................................................................................................... 2 1.1 Changes ............................................................................................................................................ 2 2.0 LOSS PREVENTION RECOMMENDATIONS ....................................................................................... 2 2.1 Introduction ...................................................................................................................................... 2 2.2 Construction and Location ............................................................................................................... 2 2.3 Occupancy ....................................................................................................................................... 3 2.4 Protection ......................................................................................................................................... 3 2.4.1 General .................................................................................................................................. 3 2.4.2 Arrangement of Sprinkler and Water Spray Systems ........................................................... 4 2.4.3 Protection of Piping, Valves and Fittings Against Damage from Explosions ........................ 6 2.4.4 Water Supply ......................................................................................................................... 6 2.4.5 Drainage ................................................................................................................................ 7 2.5 Equipment and Processes .............................................................................................................. 7 2.6 Operation and Maintenance ............................................................................................................ 7 3.0 SUPPORT FOR RECOMMENDATIONS ............................................................................................... 7 3.1 General ............................................................................................................................................ 7 3.2 Test Data ......................................................................................................................................... 7 4.0 REFERENCES ....................................................................................................................................... 8 4.1 FM Global ........................................................................................................................................ 8 4.2 Others .............................................................................................................................................. 8 APPENDIX A GLOSSARY OF TERMS ....................................................................................................... 8 APPENDIX B DOCUMENT REVISION HISTORY ....................................................................................... 8 APPENDIX C SUPPLEMENTAL INFORMATION ........................................................................................ 8 APPENDIX D NFPA STANDARD ................................................................................................................ 9

List of Figures
Fig. 1. Accidental Release Control Systems and Valving. ............................................................................ 4 Fig. 2. Indoor processing Structures. Arrangement of sprinkler and water spray protection. ....................... 5 Fig. 3. Outdoor processing structures. Arrangement of sprinkler and water spray protection. ..................... 5

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7-14 Fire & Explosion Protection for Process Structures

Page 2 FM Global Property Loss Prevention Data Sheets

1.0 SCOPE This data sheet covers fire and explosion protection of indoor and outdoor areas involving processing equipment; and supporting structures handling flammable liquids, flammable gases, and liquefied flammable gases. It does not apply to flammable liquid mixing areas only or small scale flammable liquid occupancies in conventional manufacturing or utility plants. 1.1 Changes May 2004. References to various applicable ANSI/ASME standards were updated. 2.0 LOSS PREVENTION RECOMMENDATIONS 2.1 Introduction The following guidelines should be followed, as applicable, for the protection of indoor and outdoor areas involving processing equipment and supporting structures handling flammable liquids, flammable gases, and liquefied flammable gases. Data Sheet 7-32, Flammable Liquid Operations. Data Sheet 7-43/17-2, Loss Prevention in Chemical Plants. Data Sheet 7-44/17-3, Spacing of Facilities in Outdoor Chemical Plants. Data Sheet 7-45, Instrumentation and Control in Safety Applications. Data Sheet 7-46/17-11, Chemical Reactors and Reactions. Data Sheet 7-47, Physical Operations in Chemical Plants. Data Sheet 7-49/12-65, Emergency Venting of Vessels. Data Sheet 7-59, Inerting and Purging of Tanks, Process Vessels, and Equipment. Data Sheet 7-95, Compressors. 2.2 Construction and Location 2.2.1 Preferably locate process structures in the open with a minimum of enclosure. Any enclosures should be of damage-limiting construction. (See Data Sheet 1-44, Damage-Limiting Construction.) 2.2.2 Process structure areas or buildings should be separated from other important areas or buildings by at least 100 ft (30 m). For guidance on separation, see Data Sheet 7-43/17-2, Loss Prevention in Chemical Plants, under Plant Layout; and Data Sheet 7-44/17-3, Spacing of Facilities in Outdoor Chemical Plants. 2.2.3 Preferably locate equipment (vessels, pumps, etc.) with flammable liquid holdup at ground level and provide solid floors with curbing and drainage rather than open steel grating beneath such equipment when located at upper levels. This is particularly desirable for enclosed process structures or partially enclosed process structures having roofs. 2.2.4 For process areas where there is a greater than average explosion hazard or severe three-dimensional fire hazard, main structural steel and equipment supports (load-bearing members) should be fireproofed with a material having at least a two-hour fire resistance rating, explosion resistance, weathering resistance when outdoors, corrosion resistance as needed, and be capable of withstanding direct application of large fire hose streams. A greater than average explosion hazard exists under any of the following conditions: 1. a) Processes located inside buildings using flammable liquids or gases at such temperature that an escape from the equipment will result in the formation of an explosive concentration sufficient to cause major explosion damage. b) Processes located outdoors utilizing large quantities of flammable liquids or gases at high temperatures and/or high pressures, where release of flammable vapors can be expected to cause severe and widespread damage, such as in an unconfined vapor cloud explosion.

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Fire & Explosion Protection for Process Structures 7-14

FM Global Property Loss Prevention Data Sheets Page 3

2. Processes utilizing equipment of large volume and low strength which must be taken through the explosive range at periodic intervals for maintenance or operating purposes. 3. Reactions involving any unstable materials. 4. Processes which are subject to frequent explosion incidents such as some phenolic resin reactions. 2.3 Occupancy 2.3.1 Follow the guidelines of Data Sheet 7-43/17-2, Loss Prevention in Chemical Plants, under Chemical Plant Process Hazards and Process Equipment Design for process and equipment design. 2.3.2 Flammable liquid pumping and piping systems should be installed and arranged in accordance with Data Sheet 7-32, Flammable Liquid Operations. 2.3.3 Provide process equipment with block or isolation valves, vents to flare stacks or incinerators (i.e., depressurization system), dump or salvage systems, and quench or purging systems to minimize the quantity of hazardous material released in the event of equipment failure or accident. The exact type, extent, and arrangement of such protective equipment will be dependent upon the process involved. See Figure 1 for a generalized arrangement.

Fig. 1. Accidental release control systems and valving.

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7-14 Fire & Explosion Protection for Process Structures

Page 4 FM Global Property Loss Prevention Data Sheets

2.4 Protection 2.4.1 General Sprinkler or directional water spray protection in accordance with this data sheet is needed where quantities of flammable liquids or liquefied flammable gases are sufficient to cause substantial damage in the event of fire. In general, these quantities would be approximately 200 gal (757 dm3) for any one container or 2000 gal (7570 dm3) in separate containers over a base area of 2500 ft2 (232 m2) for indoor locations. Indoor locations handling quantities less than these should be protected in accordance with Data Sheet 7-32, Flammable Liquid Operations. For outdoor locations, these amounts would be approximately two to two and onehalf times as great. For outdoor locations handling quantities less than these, localized protection may be acceptable (i.e., hose streams or monitor nozzles where personnel for fire fighting is limited). Structures and equipment handling unstable materials need special consideration and nearly always require protection. Types of Systems Closed Heads. Standard Approved high temperature-rated wet pipe automatic sprinklers or water spray nozzles can be used when the occupancy to be protected is located inside buildings. Deluge or preaction systems should be used inside if necessary to provide protection against freezing. Dry pipe systems are not acceptable. Closed head sprinklers and nozzles are not suitable for outdoor protection because of wind effects and delayed actuation, but are acceptable in open structures having solid decks if noncombustible draft curtains are provided extending down a minimum of 5 ft (1.5 m) from solid decks. Open Heads. Open head deluge sprinkler or water spray systems should be used within structures having no walls - with or without roofs - because of probable delayed action with standard closed head systems. When water spray nozzles are used, discharge pressure should not be less than the minimum required for effective operation of all nozzles. Actuating devices should be such that the water control valve will open if the actuating system is ruptured by an explosion or other accident. In addition to the manual tripping capability at the deluge valve, at least one manual remote station should be provided, preferably located in the process control room or process control area. Where system actuation lines are grouped, they should be protected against explosion damage. Water spray nozzles, where provided, should be placed to provide direct impingement of water on processing equipment and supporting structures in accordance with Data Sheet 4-1N, Fixed Water Spray Systems for Fire Protection, under Exposure Protection. Approved water spray nozzles are particularly applicable for local cooling of beams, columns, and processing equipment. Foam-water sprinklers can protect some process structures; however, their limited effectiveness against three-dimensional spill fires, foam quantity limitations, and normally lower discharge densities frequently make their use inadvisable. 2.4.2 Arrangement of Sprinkler and Water Spray Systems 2.4.2.1 For processing structures located indoors, provide area protection below all roofs and operating levels, whether solid or grated. Additional protection should be provided for any equipment, equipment supports, and structural steel located more than 15 ft (4.6 m) below any level of area protection where flammable liquids can accumulate (Fig. 2). 2.4.2.2 For processing structures located outdoors, provide either area protection or directional water spray protection. Physical arrangement of the processing structure and equipment will determine which type of protection is more practical. Protection should be provided at least to a height of 10 ft (3.0 m) above normal flammable liquid levels within the vessels or up to 30 ft (9.1 m) above the height where substantial quantities of flammable liquids may accumulate, whichever is higher (Fig. 3). Flammable liquid holdup in trays of distillation columns should not be considered accumulations of substantial quantities of flammable liquids. For area protection, follow the recommended protection arrangement for processing structures located indoors, subject to the aforementioned height limitation. Any solid operating level or roof should have area protection directly beneath. Area protection will protect a maximum of 15 ft (4.6 m) beneath it.

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Fire & Explosion Protection for Process Structures 7-14

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Fig. 2. Indoor processing structures. Arrangement of sprinkler and water spray protection.

Fig. 3. Outdoor processing structures. Arrangement of sprinkler and water spray protection.

2.4.2.3 For any process area, provide protection below any obstruction to water distribution which exceeds 3 ft (0.9 m) in width or diameter and 10 ft2 (0.9 m2) in area. Important structural members or equipment below obstructions of smaller size may need additional protection against flame impingement. Unless completely fireproofed, protection is needed inside the skirts of columns or similar self supporting vessels. 2.4.2.4 Pipe racks within 20 ft (6.1 m) of process structures are considered part of the structure and require the same protection. Pipe racks further than 20 ft (6.1 m) from a process structure may need protection in the form of sprinklers, water spray, two-hour rated fireproofing, or a combination thereof depending upon the loss potential. 2.4.2.5 Sprinkler spacing should not exceed 100 ft2 (9.2 m2) per head. Water spray nozzles should be arranged according to accepted FM Global Engineering and Research practice for water spray fixed systems for fire protection. 2.4.2.6 Pipe sizes should be calculated, or the pipe schedule for deluge systems or extra hazard occupancy should be used.

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7-14 Fire & Explosion Protection for Process Structures

Page 6 FM Global Property Loss Prevention Data Sheets

Note: Where main structural steel and equipment supports (load-bearing members) are fireproofed with a material having a fire resistance rating of two hours or more, additional water protection is unnecessary for these supports. 2.4.3 Protection of Piping, Valves and Fittings Against Damage from Explosions 2.4.3.1 Risers should be located in areas cut off by pressure resistant walls or shielded by structural columns. 2.4.3.2 Feed and cross mains should be located away from reactors or pressure vessels insofar as it is practical (e.g., in the aisles or off to the sides of reactors or pressure vessels but never directly above this equipment). 2.4.3.3 Generally, water supply mains to hazardous process areas should be buried, looped, and equipped with divisional valves so that any breaks due to explosion damage can be isolated. 2.4.3.4 All piping over 2 in. (51 mm) should be welded or have welded flanged fittings. Welding should conform to the ANSI/ASME standard for pressure piping, B31.1 Power Piping. Welded flanged fittings should conform to ANSI/ASME Standard B16.9 Factory-Made Wrought Steel Buttwelding Fittings; or ANSI/ASME Standard B16.25, Buttwelding Ends. Welding should be prohibited in an occupied structure; however, welded subassemblies may be prepared outside the area and assembled (flanged) within the area. Piping 2 in. (51 mm) or smaller may be welded; otherwise malleable iron on steel fittings of 150 lb steam rating (300 lb W.O.G. rating) should be used. These fittings should conform to ANSI/ASME Standard B16.3, Malleable Iron Threaded Fittings, 150 and 300 lb; or ANSI/ASME Standard B16.5, Steel Pipe Flanges and Flanged Fittings. Flexible couplings should not be used. 2.4.3.5 Piping should be supported from the building or structural framework; however, outdoor piping may be attached to self-supporting process equipment. 2.4.3.6 For processing structures located indoors or outdoors, a readily accessible manual shutoff valve should be provided for each system. All manual shutoff valves and automatic sprinkler control valves (alarm check, deluge, etc.) should be located at least 50 ft (15.2 m) from the building or structures. 2.4.4 Water Supply 2.4.4.1 Density. For area protection of processing structures located indoors, the following densities should be provided as illustrated in Figure 2. 1. 0.30 gal/min/ft2 (12 mm/min) at each protection level above a solid floor or level. 2. 0.30 gal/min/ft2 (12 mm/min) under any solid intermediate level or roof. 3. 0.15 gal/min/ft2 (6 mm/min) under all other levels. For area protection of processing structures located outdoors, provide 0.30 gal/min/ft2 (12 mm/min) per required protection level (Fig. 3). For directional water spray protection, provide densities according to accepted FM Global Engineering and Research practice for water spray fixed systems for fire protection. (Refer to exposure protection section in Data Sheet 4-1N, Fixed Water Spray Systems for Fire Protection.) 2.4.4.2 Demand. For processing facilities located outdoors, assume the fire protection system over the fire origin will open along with all other fire protection systems within 100 ft (30 m) of its extremities. For processing facilities located indoors, assume all heads will open within the building for ground floor areas up to 10,000 ft2 (929 m2). If open head deluge sprinkler or water spray systems are provided, assume all systems will operate. In addition to the above water requirements, include any hose streams and/or monitor nozzles likely to be used to determine the total water demand. The use of monitor nozzles in excess off 500 gal/min (1900 dm3) when fixed protection is operating normally may seriously reduce water supplies for fixed systems and should be discouraged unless water supplies are designed for additional flow. 2.4.4.3 Duration. The water supply should be capable of maintaining discharge and pressure requirements until the flammable liquid flow can be shut off and the area drained or the flammable liquid is consumed. Requirements will vary with each installation, but should be at least two hours.

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2.4.5 Drainage 2.4.5.1 Processing areas should be provided with emergency drainage to an acceptable location. For guidance refer to Data Sheet 7-83, Drainage Systems for Flammable Liquids, and Data Sheet 4-1N, Fixed Water Spray Systems for Fire Protection. Each drained area should not exceed 5000 ft2 (465 m2). The drainage system should be capable of handling all anticipated sprinkler and/or water spray discharge and hose stream water. 2.5 Equipment and Processes 2.5.1 Instrumentation should be provided and arranged according to the guidelines of Data Sheet 7-43/ 17-2, Loss Prevention in Chemical Plants. 2.6 Operation and Maintenance 2.6.1 Inspection and maintenance procedures, operator training, and emergency procedures should be performed according to the guidelines of Data Sheet 7-43/17-2, Loss Prevention in Chemical Plants. 3.0 SUPPORT FOR RECOMMENDATIONS 3.1 General Processing facilities where flammable liquids, flammable gases, and liquefied flammable gases are used in quantity can be protected from fire with insulation and fixed protection such as automatic sprinklers, water spray, and monitor nozzles. Explosion damage can be minimized by using open construction or damagelimited construction with adequate spacing or separation. Fires within such facilities may be open tank fires, spray fires from liquids under pressure, gas fires from escaping gases or vaporizing liquefied flammable gases, or combinations of these. Liquids escaping from equipment will gravitate to lower levels, exposing other equipment in the structure; multilevel fires of all types are possible. Equipment explosions can also occur due to fire exposure. Explosions within such facilities may also occur due to runaway chemical reactions with or without an ensuing fire, or from escaping gases or vapors, particularly within an enclosed area. Unconfined vapor cloud explosions are also possible in congested open process facilities where large quantities of flammable liquids are handled at elevated temperatures and pressures. For more descriptive detail on vapor cloud explosions, see Data Sheet 7-42, Guidelines for Evaluating the Effects of Vapor Cloud Explosions Using a TNT Equivalency Method. Water will not, in general, extinguish fires in flammable gases, liquefied flammable gases, and flammable liquids having flash points below 200F (93C). Automatic sprinklers and/or water spray will, however, provide a combination of general area cooling and actual wetting of equipment and structures, thereby preventing weakening of metal by overheating. The cooling and wetting also will prevent load displacement caused by thermal expansion of structural members and rupture of process tanks and piping. 3.2 Test Data FM Global Engineering and Research conducted a fire test program to evaluate the effectiveness of foamwater sprinkler protection, standard sprinkler protection, and combinations of both for a multilevel flammable liquid process steel structure 40 ft (12.2 m) high. Two basic types of fire tests using heptane as a fuel source were conducted, two-dimensional floor spill fires, and three-dimensional spill fires involving a fuel spill at an upper level of the process structure. Three important findings of the test program were 1) three-dimensional (i.e., upper open level) spill fires create a more severe fire exposure than floor spill fires; 2) foam-water sprinklers at a 0.16 gal/min/ft2 (6.5 mm/min) density can help control a floor spill fire quickly but are not very effective in reducing exposure from a three-dimensional (i.e., upper open level) spill fire; 3) foam-water sprinklers at a 0.16 gal/min/ft2 (6.5 mm/min) density and/or standard sprinklers installed in accordance with these guidelines can protect process structures against floor spill fires. The results of these findings indicate that fire protection guidelines for process structures should emphasize locating equipment with flammable liquid holdup at ground level and providing solid floors with curbing and drainage rather than open steel grating beneath such equipment when located at upper levels.

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7-14 Fire & Explosion Protection for Process Structures

Page 8 FM Global Property Loss Prevention Data Sheets

4.0 REFERENCES 4.1 FM Global Data Sheet 1-44, Damage-Limiting Construction. Data Sheet 4-1N, Fixed Water Spray Systems for Fire Protection. Data Sheet 7-32, Flammable Liquid Operations. Data Sheet 7-42, Guidelines for Evaluating the Effects of Vapor Cloud Explosions Using a TNT Equivalency Method. Data Sheet 7-43/17-2, Loss Prevention in Chemical Plants. Data Sheet 7-44/17-3, Spacing of Facilities in Outdoor Chemical Plants. Data Sheet 7-45, Instrumentation and Control in Safety Applications. Data Sheet 7-46/17-11, Chemical Reactors and Reactions. Data Sheet 7-47, Physical Operations in Chemical Plants. Data Sheet 7-49/12-65, Emergency Venting of Vessels. Data Sheet 7-59, Inerting and Purging of Tanks, Process Vessels, and Equipment. Data Sheet 7-83, Drainage Systems for Flammable Liquids. Data Sheet 7-95, Compressors. 4.2 Others ANSI/ASME B16.3, Malleable Iron Threaded Fittings. ANSI/ASME B16.5, Steel Pipe Flanges and Flanged Fittings. ANSI/ASME B16.9, Factory-Made Wrought Steel Buttwelding Fittings. ANSI/ASME B16.25, Buttwelding Ends. ANSI/ASME B31.1, Power Piping. APPENDIX A GLOSSARY OF TERMS Approved: references to Approved in this data sheet means the product and services have satisfied the criteria for FM Approval. Refer to the Approval Guide, a publication of FM Approvals, for a complete listing of products and services that are FM Approved. APPENDIX B DOCUMENT REVISION HISTORY January 2000. This revision of the document has been reorganized to provide a consistent format. APPENDIX C SUPPLEMENTAL INFORMATION Processing facilities, particularly within chemical plants, involve structures which vary widely in shape and size. Some have neither walls nor roofs, but often have high elevations and small floor areas. Work floors of solid construction or open-grating construction may be located at various levels. Such floors may be incomplete or penetrated by stairs, elevator shafts, piping and equipment. Tanks, reactors, condensers, stills and pipe racks may be arranged irregularly throughout or adjoining the structures. Typical of such facilities are petrochemical plants, pharmaceutical plants, solvent extraction plants, agricultural chemical plants, and plastics manufacturing plants.

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APPENDIX D NFPA STANDARD There is no specific NFPA standard for protection of flammable liquid processing equipment and supporting structures. There are no conflicts with related NFPA standards.

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