OISD 116 Latest

Sr.
Number:OISD/DOC/2013/158
Page No. I
OISD STANDARD - 116

Second Edition, August 2007
st
1 Amendment (July’ 08)
2nd Amendment (Oct’ 10)
3rd Amendment (July’ 12)
FOR RESTRICTED CIRCULATION ONLY
FIRE PROTECTION FACILITIES
FOR
PETROLEUM REFINERIES & OIL/GAS PROCESSING PLANTS
OISD – STD – 116

st
nd
2 Amendment (Oct’ 10)
rd
Oil Industry Safety Directorate

Government of India
Ministry of Petroleum & Natural Gas
8th Floor, OIDB Bhavan, Plot No. 2, Sector – 73, Noida – 201301 (U.P.)
Website: www.oisd.gov.in
Tele: 0120-2593800, Fax: 0120-2593802
Sr.Number:OISD/DOC/2013/158
Page No. II
OISD STANDARD - 116

1st Amendment (July’ 08)
2nd Amendment (Oct ’10)
3rd Amendment (July’ 12)
FOR RESTRICTED CIRCULATION ONLY
FIRE PROTECTION FACILITIES

FOR
PETROLEUM REFINERIES AND OIL/GAS PROCESSING
PLANTS
Prepared by
COMMITTEE ON FIRE PROTECTION
OIL INDUSTRY SAFETY DIRECTORATE

8th Floor, OIDB Bhavan,
Plot No. 2, Sector - 73
Noida – 201301 (U.P.)
Page No. III
Preamble
Indian petroleum industry is the energy lifeline of the nation and its continuous performance is
essential for sovereignty and prosperity of the country. As the industry essentially deals with
inherently inflammable substances throughout its value chain – upstream, midstream and
downstream – Safety is of paramount importance to this industry as only safe performance at all
times can ensure optimum ROI of these national assets and resources including sustainability.
While statutory organizations were in place all along to oversee safety aspects of Indian petroleum
industry, Oil Industry Safety Directorate (OISD) was set up in 1986 Ministry of Petroleum and Natural
Gas, Government of India as a knowledge centre for formulation of constantly updated world-scale
standards for design, layout and operation of various equipment, facility and activities involved in this
industry. Moreover, OISD was also given responsibility of monitoring implementation status of these
standards through safety audits.
In more than 25 years of its existence, OISD has developed a rigorous, multi-layer, iterative and
participative process of development of standards – starting with research by in-house experts and
iterating through seeking & validating inputs from all stake-holders – operators, designers, national
level knowledge authorities and public at large – with a feedback loop of constant updation based on
ground level experience obtained through audits, incident analysis and environment scanning.
The participative process followed in standard formulation has resulted in excellent level of
compliance by the industry culminating in a safer environment in the industry. OISD – except in the
Upstream Petroleum Sector – is still a regulatory (and not a statutory) body but that has not affected
implementation of the OISD standards. It also goes to prove the old adage that self-regulation is the
best regulation. The quality and relevance of OISD standards had been further endorsed by their
adoption in various statutory rules of the land.
Petroleum industry in India is significantly globalized at present in terms of technology content

requiring its operation to keep pace with the relevant world scale standards & practices. This
matches the OISD philosophy of continuous improvement keeping pace with the global
developments in its target environment. To this end, OISD keeps track of changes through
participation as member in large number of International and national level Knowledge Organizations
– both in the field of standard development and implementation & monitoring in addition to updation
of internal knowledge base through continuous research and application surveillance, thereby
ensuring that this OISD Standard, along with all other extant ones, remains relevant, updated and
effective on a real time basis in the applicable areas.
Together we strive to achieve NIL incidents in the entire Hydrocarbon Value Chain. This, besides
other issues, calls for total engagement from all levels of the stake holder organizations, which we, at
OISD, fervently look forward to.
Jai Hind!!!
Executive Director
Oil Industry Safety Directorate

Page No. IV
FOREWORD
Petroleum Refining & Gas Processing operations and its management is challenging because of large
numbers of processing units in the facility coupled with storage, handling of inflammable petroleum
products. Refineries comprise of Crude & vacuum Distillation units along with a number of complex ,
secondary units like Catalytic Reforming ,Fluidized catalytic cracking , Delayed Cokers ,Vis-Breaker ,
Hydrotreater, Hydrocraker & Hydrogen Units including process like Sulphur Recovery units and
facilities like Flare etc . Refining units as well as Gas processing facilities are subjected to operations
at high temperature and high pressures conditions and present its own set of challenges requiring
focused approach with respect to safety to sustain smooth operation and ensure supply of petroleum
products in the hydrocarbon value chain. Refineries & Gas processing play a pivotal role in ensuring
product availability and continuous safe operation of these units is a national imperative.
Even though Petroleum refineries & Gas processing plants are generally located in remote areas ,
experience shows that residential /industrial units come up in close proximity with the passage of time
. Hence these installations which process ,store & handle large quantity of flammable materials may
also pose threat to surroundings as well in addition to their own safety .Such conditions therefore
necessitate the introduction of inbuilt fire protection facilities which would ensure adequacy in terms
of its ability to contain any incident from developing into a catastrophe while achieving optimality in
terms of life cycle cost of installation, operation and maintenance.
This standard was first released in 1991. Subsequently, with the adoption of new process &
technology especially the secondary processing facilities coupled with capacity augmentation of
existing facilities increased the complexity of the installations which necessitated up-gradation of this
standard and the sequent revision was issued in Aug 2007. Further amendments to the same were
issued in July 2008 and last in October 2010 which emanated out of the in-depth analysis of the
recent major fire incident by an expert committee.
This amendment, issued now in July 2012, incorporates the duly optimized recommendations, over
and above the October 2010 amendment, emanating out of the in-depth analysis by a series of high
power committees constituted in this context in addition to the view of the Safety Council of OISD. In
this amendment, substantive additions had been made to bring more clarity in critical firefighting and
mitigating systems after optimizing the same. Attempts had also been made to align the standard to
international codes of design, practice and certification.
We, at OISD, are confident that the provisions of this standard, when implemented in totality, would
go a long way in ensuring safe operation of the target group of locations.
Needless to mention, this standard, as always would be reviewed periodically based on field level
experience, incident analysis and environment scanning. Suggestions from all stake holders are
fervently solicited.
Page No. V
NOTES
OISD (OIL INDUSTRY SAFETY DIRECTORATE)

publications are prepared for use in the oil and gas industry
under Ministry of Petroleum & Natural Gas. These are the
property of Ministry of Petroleum and Natural Gas and shall
not be reproduced or copied and loaned or exhibited to
others without written consent from OISD.
Though every effort has been made to assure the

accuracy and reliability of the data contained in these
documents, OISD hereby expressly disclaims any liability or
responsibility for loss or damage resulting from their use.
These documents are intended only to supplement and

not to replace the prevailing statutory requirements.
Page No. VI
FUNCTIONAL COMMITTEE
(First Edition - March, 1991)
Name Designation / Organisation Status

S/Shri
1. M.M.Kapoor Engineers India Limited Leader
(w.e.f. 1.1.95)
R.P. Bhatla Engineers India Limited Leader
(upto 31.12.94)
2. A.A. Raichur Hindustan Petroleum Member
Corporation Limited
3. S. Neelkanthan Madras Refineries Member
Limited
4. P.J. Joshuva Cochin Refineries Member
Limited
5. Sunil Kumar Indian Oil Corporation Member
Limited
6. V.P. Vaidhya Hindustan Petroleum Member
Corporation Limited
7. S.N. Mukharjee Bharat Petroleum Member
Corporation Limited
8. A.K. Das Bongaigaon Refineries Member
& Petrochemicals Ltd.
9. R.P. Saxena Oil & Natural Gas Member
Corporation Ltd.
10. H.K. B. Singh IBP Co. Ltd. Member
11. Vijay M. Ranalkar Oil Industry Safety Member
Directorate Coordinator
In addition to the above, several other experts from industry contributed in the preparation,
review and finalisation of the document.
Page No. VII
FUNCTIONAL COMMITTEE
(Second Edition - March 2007)
Name Organisation
LEADER
Shri Arvind Kumar Engineers India Limited, New Delhi
MEMBERS
Shri A.A. Raichur Hindustan Petroleum Corporation Limited, Mumbai.
Shri S. P. Garg GAIL (India) Limited, Pata (UP).
Shri G. B. Tolmore Indian Oil Corporation Limited, New Delhi.
Shri G. C. Kundu Indian Oil Corporation Limited, Panipat.
Shri S.N. Mukherjee Bharat Petroleum Corporation Limited. Mumbai.
Shri P. K. Bora Bongaigaon Refineries & Petrochemicals Ltd,
Bongaingaon.
Shri A.K. Das Kochi Refineries Limited, Kochi.
Shri K. V. Singh Hindustan Petroleum Corporation Limited, Vizag.
Shri J.P.K.Hepat Chennai Petroleum Corporation Limited, Chennai.
Shri D. K. Varshney Oil Industry Safety Directorate, New Delhi.
MEMBER COORDINATOR
Shri P. Kulshreshtha Oil Industry Safety Directorate, New Delhi.
In addition to the above, several other experts from industry contributed in the
preparation, review and finalisation of the document.
Page No. VIII
FIRE PROTECTION FACILITIES FOR PETROLEUM

REFINERIES AND OIL/GAS PROCESSING PLANTS
SL.NO. DESCRIPTION PAGE NO.

1.0 Introduction 1
2.0 Scope 1
3.0 Definitions 2
4.0 Fire Protection philosophy 3
4.1 General considerations 4
4.2 Design criteria 4
5.0 Fire Water System 6
5.1 Basis 6
5.2 Firewater Flow Rate 6
5.3 Header Pressure 7
5.4 Storage & Make up water 7
5.5 Firewater Pumps 7
5.6 Distribution Network 9
5.7 Hydrants and Monitors - Details 10
5.8 Material Specifications 12
5.9 Fixed Water Spray System 13
5.10 Fixed Water Sprinkler System 14
6.0 Foam Systems 14
6.1 Types of Foam 14
6.2 Low Expansion Foam 14
6.3 Foam Conveying Systems 15
6.4 Floating Roof Tank Protection using foam 16
6.5 Fixed Roof Tank Protection using foam 16
6.6 Floating cum Fixed Roof Tank Protection using foam 16
6.7 Dyke Area/Spill/Oil Separator Protection using foam 17
6.8 Foam Application Rate 17
6.9 Duration of Foam Discharge 17
6.10 Foam Quantity Requirement 17
6.11 Foam Compound Storage 17
7.0 Clean Agent Based Protection System For Control Room, SPR And 18
Computer Room Protection
8.0 Carbon Dioxide Systems 18
9.0 Dry Chemical Extinguishing System 19
9.1 Recommended use 19
9.2 System Design 19
10.0 Modernization plan for firefighting equipments 19
11.0 First Aid Fire-fighting & other Equipment 20
11.1 Criteria to determine the Quantity needed 20
11.2 Other fire fighting Equipment 22
12.0 Mobile Fire-fighting Equipment 22
12.1 Fire Tenders 22
12.2 Other Mobile Equipment 22
12.3 Other Fire Fighting Equipment 23
13.0 Storage of Fire Fighting Agents 23
14.0 Detection system and Alarm 25
14.1 Areas to be covered with detectors 25
15.0 Communication System 26
16.0 Inspection & Testing of Fire Protection System 27
16.1 Fire water tank, reservoir & foam tanks 27
16.2 Fire Water Pumps 27
16.3 Fire Water Ring Main 28
16.4 Fire Water Spray System 28
Page No. IX
SECTION DESCRIPTION PAGE NO.

16.5 Fixed/Semi Fixed Foam System 28
16.6 Clean Agent (Halon Substitute) based Extinguishing System 28
16.7 Mobile Fire Fighting Equipment and Accessories 28
16.8 DCP / CO2 / Foam type Fire Extinguishers 29
16.9 Communication System 29
16.10 Detectors 29
17.0 Fire Fighting Organisation 29
18.0 Fire Protection Training 30
19.0 Mutual Aid 30
20.0 Fire Emergency Procedures 30
21.0 Fire Station/Control Room 31
22.0 Passive Fire Protection Measures / Other Safety measures 31
23.0 Fire Protection system Audit 32
24.0 References 32
ANNEXURES
I Example for calculation of Fire Water Flow Rate 34
Example for calculation of Foam Compound Requirement 40

II
Broad specifications for Fire Fighting Equipment 42
III
Fire Training Ground - Facilities 44
IV
Arrangement of Mutual Aid 47
V
Example Of Fire Case In A Large Floating Roof Tank After Sinking Of 49
VI Floating Roof
System of automatic actuated rim seal fire detection and extinguishing system 50
VII for external floating roof tanks storing Class- A petroleum
Brief description of fire-fighting foam 52

VIII
Explanatory Note for Implementation 55
IX
------
OISD – STD – 116 Page No. 1

FIRE PROTECTION FACILITIES FOR PETROLEUM REFINERIES
AND OIL/ GAS PROCESSING PLANTS

AND OIL/GAS PROCESSING PLANTS
1.0 INTRODUCTION
Even though petroleum refineries and oil/ gas processing installations are generally located in remote
areas, experience shows that residential/industrial units come up in close proximity with the passage
of time. Hence, these installations which store, process and handle large quantity of flammable
materials, pose threat to surroundings as well, in addition to their own safety. Such conditions,
therefore, necessitate the introduction of in-built fire protection facilities.
It is impractical and prohibitively costly to design fire protection facilities to control catastrophic fires.
Usual requirement of an effective fire protection system is to prevent emergencies from developing
into major threat to the installations and surroundings.
The requirement of fire fighting facilities, described in the following chapters is based on the
consideration that the fire fighting services from city fire brigade and/or from other neighbouring
industries will not be available.
2.0 SCOPE
i) This standard covers the minimum design criteria and details of the various fire protection
facilities to be provided in petroleum refineries and oil/gas processing plants.
ii) This standard also covers the facilities located within the refineries and oil/ gas processing plants
which includes:
 LPG storage, handling and bottling plants,
 Marketing & Pipeline Terminals with their loading / un-loading/ pumping and handling
facilities
iii) This standard does not cover the facilities located outside the premises of Refineries & gas
processing plants such as LPG mounded storage, handling & bottling plants, LNG storage
Petroleum Depots, Terminals, Lube Blending plants & Pipeline Installations located out side.
However, this standard shall be applicable to those of above mentioned facilities located outside
the premises under the same management and in close proximity to the refineries & gas
processing plants. For such cases, common firewater storage and pumping facilities should be
considered.
Otherwise, to protect the facilities located outside the following OISD standards shall apply:
 LPG storage, handling & bottling plants --- under OISD-STD-144 & OISD-GDN-169.
Mounded storage – under OISD-STD-150.
 Petroleum Depots, Terminals, AFS, Lube Blending plants & Pipeline Installations ---
under OISD-STD-117.
 Central Tank Farm (CTF) --- OISD-STD – 117.
 Group Gathering Station (GGS), Oil Collecting Stations (OCS) --- under OISD-STD-
189.
iv) Wherever specified in the standard, the use of equivalent or superior performance systems /
methods to those already prescribed in the standard, should be considered, provided these
equivalent systems / methods are duly approved by a technical committee constituted by OISD,
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”

based upon technical documentation, performance record and field demonstration by the user
industry.
v) It is intended that the provisions specified in this standard shall be implemented progressively for
the existing facilities.
For the new/upcoming locations, these shall be implemented along with commissioning of the
tank.
The replacement of the extant Rim seal fire protection system in the existing Class “A” floating
roof tanks would be governed by equivalency clause as given in the standard.
(Refer Explanatory Note for Implementation in Annexure-IX).
3.0 DEFINITIONS
i) PETROLEUM REFINERY
A plant where crude oil is received and processed to produce various intermediates and
finished products.
ii) OIL/GAS PROCESSING PLANT
A plant where oil/natural gas is collected and processed to produce Oil/LPG and other
petroleum fractions. Drilling activities and facilities upstream of the Christmas tree of a well
are not covered under this definition.
iii) LPG BOTTLING PLANT
A plant where LPG is stored and filled into cylinders. Receipt and despatch of LPG by rail,
road and pipeline are also considered under this definition.
iv) PETROLEUM DEPOTS, TERMINALS AND OIL & GAS INSTALLATIONS
These include locations where Petroleum crude/Products/LPG are received by tanker,

pipelines, tank wagons and tank trucks and stored or blended in bulk and despatched by
tankers, pipelines, tank wagons, tank trucks, portable tanks or containers. Lube oil
installations including lube blending plant / Grease manufacturing plants and can-filling
facilities also form part of such installations.
v) INSTALLATION
For the purpose of this Standard, installation includes all the facilities as listed in 3(i) to 3(iv)
which are located in a Refinery or Oil/Gas Processing Plant.
vii) FLASH POINT:
The minimum temperature at which the liquid gives so much vapour that this vapour, when
mixed with air, forms an ignitable mixture and gives a momentary flash on application of a
small pilot flame under specified conditions of test.
viii) CLASSIFICATION OF PETROLEUM PRODUCTS
a) General Classification of Petroleum Products:
Petroleum products are classified according to their closed cup FLASH POINTS as follows:
Class 'A' Petroleum: Liquids having flash point below 23 degrees C.

Class 'B' petroleum: Liquids having flash point of 23 degrees C and above but below 65
degrees C.
Class 'C' petroleum : Liquids having flash point of 65 degrees C and above but below 93
degrees C.
Excluded Petroleum: Liquids having flash point of 93 degrees C and above.
Liquefied gases including LPG, do not fall under this classification but form a separate
category.
b) Classification for heated products :
At locations where the handling temperatures are higher than the flash point of the product in
circumstances where product handled is artificially heated to above its flash point, class 'C'
product shall be considered as Class 'B' product and Class 'B' product shall be considered as
Class 'A' product.
ix) CLASSIFICATION OF FIRES
Class A Fires: involve combustible materials of organic nature, such as wood, paper, rubber
and many plastics, etc., where the cooling effect of water is essential for extinction of fires.
Class B Fires: involve flammable liquids, petroleum products, or the like, where a blanketing
effect is essential.
Class C Fires: involve flammable gases under pressure including liquefied gases and
energised electrical equipment where it is necessary to inhibit the burning gas at a fast rate
with an inert gas, powder or vapourising liquid for extinguishment.
Class D Fires: involve combustible materials such as magnesium, aluminum, zinc, sodium,
potassium. The burning metals are reactive to water and water containing agents, and in
certain cases carbon dioxide, halogenated hydrocarbons and ordinary dry powders. These
fires require special media and technique to extinguish.
x) Shall: indicates provision that is mandatory in nature.
xi) Should: indicates that provision is recommendatory as per good engineering practices.
xii) Clean Agent: electrically non-conductive, volatile or gaseous fire extinguishants that does not
leave a residue upon evaporation and meets the requirements given in the latest NFPA
Standard 2001 (latest edition) on clean agent fire extinguishing systems in line with
environmental consideration of Kyoto and Montreal Protocols & latest MoEF regulations.
xiii) GPM denotes US gallons (1GPM=3.785 LPM)
4.0 FIRE PROTECTION PHILOSOPHY
The Fire Protection Philosophy is based on Loss Prevention and Control. It considers that a
hydrocarbon processing plant carries inherent potential hazard. A fire in one part/section of
the plant can endanger other sections of plant as well. If fire breaks out, it must be controlled /
extinguished as quickly as possible to minimise the loss to life and property and to prevent
further spread of fire.
4.1 GENERAL CONSIDERATIONS
The size of process plant, pressure and temperature conditions, size of storage, plant location
and terrain determine the basic fire protection need. Layout of an installation shall be done in
accordance with OISD-Standard-118 on Layouts to ensure adequate fire fighting access,
means of escape in case of fire and also segregation of facilities so that the adjacent facilities
are not endangered during a fire.
Material of construction for infrastructure facilities shall conform to National Building Code

(NBC) / statutory regulations.
The following fire protection facilities shall be provided depending upon the nature of the
installation and risk involved.
- Fire Water System

- Foam System
- Clean Agent Fire Protection system
- Carbon Dioxide System
- Dry Chemical Extinguishing System
- Detection and Alarm system
- Communication System
- Portable fire fighting equipment
- Mobile fire fighting equipment
- First Aid Fire Fighting Equipment.
4.2 DESIGN CRITERIA
The following shall be the basic design criteria for a fire protection system.
i) Facilities shall be designed on the basis that city fire water supply is not available close to
the installation.
ii) Fire protection facilities shall be designed to fight two major fires simultaneously any
where in the installation.
Fire water requirements shall be as per guidelines given in Annexure-l.
iii) All the tank farms and other areas of installation where hydrocarbons are handled shall
be fully covered by hydrant System.
4.2.1 Fixed Water Spray on storage Tanks
i) Class ‘A’ Petroleum storage in above ground tanks shall have fixed water spray system,
whether floating roof or fixed roof.
ii) Class 'B' Petroleum storage tanks of following dimensions shall be provided with fixed
water spray.
- Floating roof tanks of diameter larger than 30 M.

- Fixed roof tanks of diameter larger than 20 M.
4.2.2 Semi-fixed Foam system for Storage
i) Semi-fixed Foam system shall be provided for the following tanks:
- Floating roof tanks storing Class 'A' and Class 'B' petroleum products.
- Fixed roof tanks storing Class 'A' and class 'B' petroleum products.
- Fixed roof tanks storing class 'C' petroleum products, of diameter larger than 40 M.
4.2.3 Automatic Actuated Rim seal Protection System for External Floating roof tanks:
Automatic actuated Rim Seal fire detection and extinguishing system shall be provided on all
existing as well as new external floating roof tanks storing Class A Petroleum products.
The rim seal protection system shall be of linear hollow metallic tube type detectors with foam

based extinguishing media or equivalent system*, for existing, new installation as well as for
replacements of existing system when due. These detection systems shall be listed and/or
approved by any of the international agencies like UL, FM, VdS or LPC to ensure that those
systems are used which meet with highest standards of safety.
The minimum requirement for design of the system is given in Annexure VII. This shall be in
addition to the water spray and semi-fixed foam system on all the floating roof tanks storing
class-A products.
(Refer Explanatory Note for implementation in Annexure-IX).
* Refer clause at para 2.0 (iv) for equivalency.
4.2.4 Automatic Water Spray for Pressurised storages including LPG / Hydrogen
i) LPG and hydrogen Pressure storage vessels shall be provided with automatic water
spray system.
ii) Automatic water spray system shall be provided in LPG bottling stations, LPG
loading/unloading gantries and LPG pump and compressor areas in all new refineries
and for existing refineries this conversion to automatic shall be done in phased manner.
4.2.5 Water Spray System in Process Unit
i) Water spray system shall be provided for hazardous locations and equipment in process
unit areas. Some of these areas are:
- Un-insulated vessels having capacity larger than 50 m3 and containing class A or B
flammable liquid.
- Vessels inaccessible to fire tender/ mobile equipment, fire hydrants
- Pumps handling petroleum products class 'A' under pipe racks.
- Pumps handling products above auto-ignition temperature under pipe racks
- Air fin coolers in hydrocarbon service located above pipe racks / elevated location.
- Water spray rings for columns of height more than 45 M shall be provided
4.2.6 Water Spray for Electrical Installation
Water spray requirement with mode of operation to be considered in line with provisions of
OISD-STD-173. The water to be used should be clear and non saline.
4.2.7 Clean Agent (Halon substitute) for Control rooms & Satellite Rack Room (SRR)
Selection of Clean Agent and design of Fire protection system for process control rooms,
computer rooms, SRR and pressurized rooms shall follow the Standard on “Clean Agent
Extinguishing systems NFPA Standard 2001 (latest edition) including its safety guidelines with
respect to “Hazards to Personnel”, electrical clearance and environmental factors in line with
environmental considerations of Kyoto & Montreal Protocols and latest MoEF regulations.
Clean Agents like inert gas, Fluoro-ketone can be used as fire suppressant in Control rooms &
SRR and Computer/Server rooms. (For areas to be covered with clean agent refer OISD STD
163).
4.2.8 Loading / unloading Gantry
Oil loading/unloading Tank Truck & Tank Wagon Gantries shall be provided with water spray
and/or foam system.
In case automatic fixed water spray system is provided in TW gantry, the gantry may be
divided into suitable number of segments (each segment having min. length of 15 m length &
width of 12 m) and three largest segments operating at a time shall be considered as single risk
for calculating the water requirement.

Accordingly, a provision shall be made to actuate the water spray system from a safe
approachable central location i.e. affected zone and adjoining zones.
5.0 FIRE WATER SYSTEM
Based on the site requirement, water shall be used for fire extinguishment, fire control,
cooling of equipment and protection of equipment as well as personnel from heat radiation.
For these purposes water in appropriate form should be used such as straight jet, water fog,
water mist, water curtain, water spray, deluge/ sprinkler, for foam making etc.
Fire water system shall comprise of fire water storage, fire water pumps and distribution
piping network along with hydrants and monitors, as the main components.
5.1 BASIS
In line with the design criteria given at 4.2 (ii), the fire water system in an installation shall be
designed to meet the fire water flow requirement for fighting two fires simultaneously or single
fire for largest floating roof tank roof sinking case, whichever requiring largest water
demand.
5.2 FIREWATER FLOW RATE

Two of the largest flow rates calculated for different sections as shown below shall be added
and that shall be taken as design flow rate. An example for calculating design major fire water
flow rate is given in Annexure-1.
i) Fire Water flow rate for tank farm shall be aggregate of the following:
- Water flow calculated for cooling a tank-on-fire at a rate of 3 Ipm/m2 of tank shell area.
- Water flow calculated for all other tanks falling within a radius of (R+30) M from centre of
2
the tank on fire at a rate of 3 Ipm/m of tank shell area.
- Water flow calculated for all other tanks falling outside a radius of (R+30) M from centre
2
of the tank on fire and situated in the same dyke area at a rate of 1 Ipm/m of tank shell
area.
- Water flow required for applying foam into a single largest cone roof or floating roof tank
(after the roof has sunk) burning surface area of oil, by way of fixed foam system, where
provided or by use of water/foam monitors. (Refer section 6.8 for foam rates).
- Fire water flow rate for supplementary stream, shall be based on using 4 single hydrant
outlets and 1 HVLR (1000GPM) simultaneously. Capacity of each hydrant outlet as 36
3 3 2
m /hr and of each monitor as 228 m /hr shall be considered at a pressure of 7 kg/cm g.
ii) Fire water flow rate for LPG sphere storage area shall be aggregate of the following:
2
- Water flow calculated for cooling LPG sphere on fire at a rate of 10.2 Ipm/ m of sphere
surface area.
- Water flow calculated for all other spheres falling within a radius of (R+30) metre from
2
centre of the sphere on fire at the rate of 10.2 Ipm/ m of surface area.
3
- If the water rate as calculated above works out to be more than 2000 m /hr the layout of
the spheres should be reviewed.
3
- Water flow for supplementary stream shall be considered as 372 m /hr as indicated under

item (i).
- The spheres should be laid in two separate groups with each group limited to a maximum
of 6 vessels The groups shall preferably be separated by a distance of (R+30) metre.
iii) Water flow required for applying foam into a single largest cone roof or floating roof tank
(after the roof has sunk) burning surface area of oil, by way of fixed foam system, where
provided or by use of water/foam monitors. (Refer section 6.8 for foam rates).
iv) Water flow rate requirements for fire fighting in other major areas shall be calculated based
2
on criteria in terms of lpm/ m given in section 5.9.
5.3 HEADER PRESSURE
The fire water system shall be designed for a minimum residual pressure of 7.0 kg/cm2g at
the hydraulically remotest point of application at the designed flow rate at that point.
2
The fire water network shall be kept pressurised at minimum 7.0 kg/cm g at all the time.
5.4 STORAGE & MAKE-UP WATER
5.4.1 FIREWATER STORAGE
Water for the hydrant service shall be stored in any easily accessible surface or underground lined
reservoir or above ground tanks of steel, concrete or masonry. The fire water storage should be
located as far away as possible (not less than 60 M) from hazardous areas to avoid any damage in
case of fire/explosion. The effective capacity of the reservoir above the level of suction point shall
be minimum 4 hours aggregate working capacity of main pumps (excluding standby pumps).
Where rate of make up water supply is 50% or more, this storage capacity can be reduced to 3
hours aggregate working capacity of main pumps.
Storage reservoir shall be in two equal interconnected compartments to facilitate cleaning and
repairs. In case of aboveground steel tanks there shall be minimum two tanks each having 50 % of
required capacity.
Large natural reservoirs having water capacity exceeding 10 times the aggregate fire water
requirement can be left unlined.
In addition to fire water storage envisaged as above, emergency water supply in the event of
depletion of water storage shall be considered. Such water supplies can be connected from
cooling water supply header and/or treated effluent discharge headers.
Fire water supply shall be from fresh water source such as river, tube well or lake. Where fresh
water source is not easily available, fire water supply can be sea water or other acceptable
source like treated effluent water. In case sea water or treated effluent water is used for fire
fighting purposes, the material of the pipe selected shall be suitable for the service.
5.4.2 MAKE UP WATER
Suitable provisions shall be kept for make up firewater during fire fighting time. Provision should be
made to divert water from various sources like ETP, Process Cooling Water, river, ponds etc. to
the fire water system.
5.5 FIREWATER PUMPS

Firewater pumps shall be used exclusively for fire fighting purposes.

5.5.1 Type of Pumps
Fire water pumps shall be of the following type:
i) Electric motor driven centrifugal pumps

ii) Diesel engine driven centrifugal pumps
The pumps shall be horizontal centrifugal type or vertical turbine submersible pumps.
Each pump shall be capable of discharging 150% of its rated capacity at a minimum of 65%
of the rated head. The shut-off head shall not exceed 120% of rated head, for horizontal
pumps and 140% in case of vertical turbine type pumps.
Number of diesel driven pumps shall be minimum 50% of the total number of pumps
(inclusive of standby pumps). Minimum 50% of total flow requirement should be available
through diesel driven pumps all the time. Power supply to the electric driven pumps should be
from two separate feeders.
5.5.2 Capacity of main Pumps
The capacity and number of main fire water pumps shall be fixed based on design fire water
rate, worked out on the basis of design criteria as per section 5.2. The capacity of each pump
3 3
shall not be less than 400 m /hr or more than 1000 m /hr. All pumps should be identical with
respect to capacity and head characteristics.
5.5.3 Standby pumps
i) When total number of Working pumps work out to be one or two, 100% standby pumps
shall be provided.
ii) When total numbers of working pumps are more than two, 50% standby pumps shall be
provided.
iii) In cases where two sets of firewater storage and pumps are provided, the number of
pumps at each location shall be according to hydraulic analysis of piping network.
5.5.4 Jockey Pumps
The fire water network shall be kept pressurised at minimum 7.0 kg/cm2 g by jockey pumps. 2
Jockey pumps (1 working plus 1 standby) shall be provided. The capacity of the pump shall
be sufficient to maintain system pressure in the event of leakages from valves etc. The
capacity of jockey pumps shall be 5% minimum and maximum 10% of the design fire water
rate. Its head shall be higher than the main fire water pumps. Auto cut-in / cut-off facility
should be provided for jockey pumps
5.5.5 Power Supply for Fire Water Pumps
i) A direct feeder dedicated only to fire water pumps shall be laid from the sub-station to
ensure reliable power supply. The direct feeder line shall not run along with other HT
cables.
ii) The diesel engines shall be quick starting type with the help of push buttons located near
the pumps, or at remote location.
iii) Each diesel engine shall have an independent fuel tank adequately sized for 6 hours
continuous running of the pump.
iv) Main fire water pumps shall start automatically and sequentially with pressure
switches/PLC on fire water mains. The system shall ensure auto start of the standby
pump in case a pump in sequence failed to take start.

5.5.6 Location of pumps
Firewater pumps shall be located as far away as possible (not less than 60 M) from
hazardous areas to avoid any damage in case of fire/explosion. The location and inter-
distances for firewater pump house and related facilities shall follow OISD-STD-118.
5.6 DISTRIBUTION NETWORK
5.6.1 Looping & Maintainability

The fire water network shall be laid in closed loops as far as possible to ensure multi-
directional flow in the system. Isolation valves shall be provided in the network to enable
isolation of any section of the network without affecting the flow in the rest. The isolation
valves shall be located near the loop junctions. Additional valves shall be provided in the
segments where the length of the segment exceeds 300 M.
For ease of maintenance, Firewater pumps should be segregated in two groups by providing
an isolation valve on common discharge header of pumps.
Flushing connections with isolation valves should be provided at suitable locations in the
firewater ring main.
For branch piping, an isolation valve shall be provided at the take-off point.
Permanent connection shall not be taken from fire water line / system for purposes other than
fire protection/ fire prevention.
5.6.2 Criteria for above / underground network
The firewater network piping should normally be laid above ground at a height of atleast 300
mm above finished ground level. However, the fire water network piping shall be laid below
ground level at the following places. Pipes made of composite material shall be laid
underground.
i) Road crossings.
ii) Places where the above ground piping is likely to cause obstruction to operation and
vehicle movement, and get damaged mechanically.
iii) Where frost condition warrants, the ring main system shall be laid underground beneath
the frost layer.
5.6.3 Protection for underground pipelines
Where the pipes are laid underground the following protections shall be provided:
i) The main shall have at least one meter earth cushion in open ground and 1.5 metre earth
cushion under the roads. In case of crane movement areas, pipes should be protected
with concrete/steel encasement.
ii) The mains shall be provided with protection against soil corrosion by suitable
coating/wrapping.
iii) Pipe supports under the pipe line shall be suitable for soil conditions.

5.6.4 Protection for above ground pipelines
Where the pipes are laid above ground, the following protection shall be provided:
i) The firewater mains shall be laid on independent sleepers by the side of road. These
shall not be laid along with process piping on common sleepers.
ii) The mains shall be supported at regular intervals not exceeding 6 metre. It should be
supported at every 3 M for pipes less than 150 mm diameter.
iii) The system for above ground portion shall be analysed for flexibility against thermal
expansion and necessary expansion loops shall be provided wherever called for.
5.6.5 Hydraulic Analysis & Sizing of Firewater Network
i) The hydraulic analysis of network shall be done. Also whenever fire water demand increases
due to addition of plant & facilities or extensive extension of network, fresh hydraulic
analysis shall be carried out.
ii) Fire water distribution ring main shall be sized for 120% of the design water rate. Design
flow rates shall be distributed at nodal points to give the most realistic way of water
requirements in an emergency. Several combinations of flow requirements shall be
assumed for design of network. For large water requirement for floating roof tank
(Annexure-VI), the network around tank farm shall be suitably designed.
5.6.6 Fire hydrants
Fire water hydrants shall be provided on the fire water network (Ref. Section 5.7 for details).
Each of these connections shall be provided with independent isolation valves. Refer item
5.7.1 for further details on hydrants.
5.6.7 Fixed water monitors
Fixed water monitors shall be provided on the fire water network (Ref. Section 5.7 for details).
Each of these connections shall be provided with independent isolation valves.
5.6.8 Layout
i) Fire water mains shall not pass through buildings or dyke areas.
ii) Hydrants / monitors shall not be located inside the dyke area.
5.7 HYDRANTS & MONITORS - DETAILS

5.7.1 Hydrants
i) Hydrants shall be located keeping in view the fire hazards at different sections of the
premises to be protected and to give most effective service. At least one hydrant post
shall be provided for every 30 M of external wall measurement or perimeter of unit battery
limit in case of hazardous areas. Hydrants protecting utilities and non plant buildings can
be spaced at 45 M intervals. The horizontal range and coverage of hydrants with hose
connections shall not be considered more than 45 M.
ii) The hydrants shall be located at a minimum distance of 15 M from the periphery of
storage tank or hazardous equipment under protection. For process plants location of
hydrants shall be decided based on coverage of all areas. In the case of buildings, this
distance shall not be less than 5 M and more than 15 M from the face of building.
Provision of hydrants within buildings shall be in accordance with Standard IS Standard-

3844.
iii) Hydrants / Monitors shall be located along road side berms for easy accessibility as far as
possible.
iv) Double headed hydrants with two separate landing valves on 4" stand post shall be used.
All hydrant outlets shall be situated at a workable height of about 1.2 metre above ground
level.
v) Fire hydrants around the tank should be provided with 4” size pumper connection.
vi) Hydrants / Monitors shall be located with branch connections and not directly over main
header for easy accessibility.
5.7.2 Monitors
i) Monitors shall be located at strategic locations for protection of cluster of columns,

heaters, gassifiers, etc., and where it is not possible to approach the higher levels. A
minimum of 2 monitors shall be provided for the protection of each such area. Water
monitors for protection of heaters shall be installed so that the heater can be isolated
from the remainder of the plant in an emergency.
ii) Monitors shall be located to direct water on the object as well as to provide water shield
to firemen approaching a fire. The monitors should not be installed less than 15 M from
hazardous equipment.
iii) Field adjustable variable flow monitors shall be installed at critical locations. These shall
be UL/FM listed / approved.
The requirement of monitors shall be established based on hazard involved and layout
considerations.
The location of HVLRs to be planned in such a way that the very purpose of these
monitors is served and throw of the monitors is safely delivered at the aimed object. The
location of monitors shall not exceed 45 M from the hazard to be protected.
Monitors should be painted with luminous color for ease of identification during
emergency.
5.7.3 Dry/Wet Risers with hydrants should be provided on each floor of technological structures.
5.7.4 Fixed Remote / Manual operated High Volume Long Range Water cum Foam Monitors
Remote / Manual operated high volume long range water cum foam monitors (Capacity 1000
GPM & above) shall be variable flow type with flow adjustable manually in the field, with foam
induction to monitor being possible from minimum 60 m distance from the monitor and shall
be provided in
i) Tank farm area.
ii) Inaccessible areas such as column, reactor, compressor house etc in critical units like
CCRU, DHDS, HCU, Hydrogen, FCCU, DCU, CDU etc
iii) Critical equipments at higher locations (above 45 mtrs.)
The basic water cum foam monitors shall be UL/ FM listed / approved. The electrical or
hydraulic remote control mechanism shall be in line with Hazardous Area Classification.

Following criteria shall be followed for installation of variable flow foam-cum-water monitors in
tank farm area:
a) Remote/ manual operated variable flow monitors shall be installed in such ways that all the
tanks in the installation are within the horizontal range of foam throw.
b) Number and capacity of monitor shall be provided in such a way that foam application rate
2
from the monitors meet requirement of foam application rate (8.1 LPM/m ) for full surface
tank fire as per NFPA-11.
For determining the total foam solution requirement, potential foam loss from wind and other
factors shall be considered.
5.7.5 Hose Boxes

Provision of hose boxes should be given at critical locations for housing hoses and nozzles.
5.7.6 Water cum Foam monitors for Gantry area
Tank Wagon & Tank Lorry loading/ unloading gantry area shall be provided with alternate water
cum foam monitors having multipurpose combination nozzles for jet spray & fog arrangement
and fire hydrants located at a spacing of 30 M on either sides of the gantry. These monitors
shall be UL/FM listed / approved variable flow type.
(This is in addition to water spray requirement given in 4.2.8.)
5.8 MATERIAL SPECIFICATIONS
All the materials required for firewater system using fresh water shall be of approved type as
indicated below.
i) Pipes: Carbon Steel as per IS: 3589/ IS: 1239/IS:1978 or Composite materials as per API
15LR/API 15 HR or its equivalent shall be used.
In case saline water/ treated effluent water is used , the fire water main of steel pipes shall
be, internally cement mortar lined or glass reinforced epoxy coated or made of pipe
material suitable for the quality of water. Alternatively, pipes made of composite materials
shall be used.
Cast iron pipes shall not be used for fire water services.
ii) Isolation Valves: Cast Steel valves shall be used in all areas including unit areas, offsite
and fire water pump stations.
Isolation valves having open/close indication shall be Gate valves more than 16” should be
provided with gear mechanism.
iii) Hydrant:
Standpost: Carbon Steel
Outlet valves: Gunmetal / Aluminium Landing valves: Stainless Steel / AI-Zn Alloy/gun
metal.
iv) Monitors:
Water Monitors: Carbon Steel/ Gun Metal Foam
Monitors: stainless steel/ brass.
v) Fire Hose: Reinforced Rubber Lined Hose as per IS 636 (Type A)/Non-percolating
Synthetic Hose (Type B).
vi) In case of underground mains the isolation valves shall be located in RCC/brick masonry
chamber.
vii) The above ground fire water mains and the fire hydrant standpost shall be painted with

corrosion resistant "Fire Red" paint shade 536 of IS: 5.

viii) Water monitor and hose box shall also be painted in "Fire Red" shade 536 of IS: 5.
ix) Corrosion resistant paint shall be used in corrosion prone areas.
5.9 FIXED WATER SPRAY SYSTEM
5.9.1 General
It is a fixed pipe system connected to a reliable source of water supply and equipped with
water spray nozzles for specific water discharge and distribution over the surface of area to
be protected. The piping system is connected to the hydrant system water supply through an
automatically or manually actuated valve which initiates the flow of water.
i) Fixed water spray system should be provided in high hazard areas where immediate
application of water is required (refer 4.2.1,4.2.5,4.2.6, 4.2.8 above).
ii) Water supply patterns and their densities shall be selected according to need. Fire water
spray system for exposure protection shall be designed to operate before the possible
failures of any containers of flammable liquids or gases due to temperature rise. The
system shall, therefore, be designed to discharge effective water spray within shortest
possible time.
5.9.2 Water Spray Application Rates
The following water spray application rates are recommended for general guidance. These
rates should be reviewed on case to case basis and increased, if required. While calculating
the water rates for spray application for cases other than tanks/vessels, the area should be
divided into suitable segments so that maximum water requirement for spray application
3
should generally not exceed 1200 m /hr.
Application Area Water application rate

Atmospheric storage 3 Ipm/m2 of tank shell area for tank on fire
Tanks 3 Ipm/m2 of tank shell area for exposure protection for
tanks located within (R+30) M from centre of tank-on-
fire within the same dyke area.
2
1 Ipm/m of tank shell area for exposure protection for
tanks located outside (R+30) metre from centre of tank-
on-fire within the same dyke area.
Pressure Storage Vessels 10.2 Ipm/m2 of shell area
Process Unit Area

2
- Pumps (Volatile product service 20.4Ipm/m
located under Pipe rack)
2
- Columns, other Extremely 10.2 Ipm/m
hazardous area
LPG pump house 20.4 Ipm/m2
LPG Tank Truck & Tank Wagon 10.2 Ipm/m2

loading/ Unloading gantries
LPG Bottling plants:

2
- Carousel machine 10.2 Ipm/m

- Filled cylinder storage 10.2 Ipm/m2

- Empty cylinder storage 10.2 Ipm/m2
2
- LPG cylinder cold repair. 10.2 Ipm/m
Shed
2
Oil Tank Truck & Tank Wagon 10.2 Ipm/m
loading/unloading gantries
Cable Trays 10.2 Ipm/m2

Transformers 10.2 Ipm/m2
5.10 FIXED WATER SPRINKLER SYSTEM
i) Fixed water sprinkler system is a fixed pipe tailor made system to which sprinklers with fusible
bulbs are attached. Each sprinkler riser/system includes a controlling valve and a device for
actuating an alarm for the operation of the system. The system is usually activated by heat from
a fire and discharges water over the fire area automatically.
ii) Sprinkler systems are used for fire extinguishment when the hazards located inside buildings.
Some of the examples being:
a) Car parking in basement

b) Building/sheds storing combustible and flammable materials.
iii) The water for sprinkler system shall be tapped from plant fire hydrant system, the design of
which should include the flow requirement of the largest sprinkler installation.
iv)The design flow for sprinkler installation would depend on the type of hazard and height of piled
storage. The water flow rate for automatic sprinkler system for car parking area shall be taken
2
as 5.1 Ipm/m of the area protected by sprinkler installation. The design water flow shall be
3 3
restricted to a minimum 100 m /hr and to a maximum 200 m /hr. The design flow rate for other
2
areas shall be taken as 10.2 Ipm/ m of the area protected by sprinkler installation, subject to a
minimum of 150 m3/hr. and a maximum of 400 m3/ hr. Higher water application rates should be
used if called for depending on risk involved.
6.0 FOAM SYSTEMS
6.1 TYPES OF FOAM
For detailed description of Fire Fighting Foam Compounds, please refer Annexure-VIII.
6.2 LOW EXPANSION FOAM
For combating large hydrocarbon fires particularly in a contained area like storage tank, foam
has proved useful for its inherent blanketing ability, heat resistance and security against burn-
back. Aqueous Film Forming Foam (AFFF) compound is technically superior and compatible
with other fire fighting agents.
Efficient and effective foam delivery system is a vital tool for its usefulness in controlling the
fire.
The process of adding or injecting the foam to water is called proportioning. The mixture of
water and foam compound (foam solution) is then mixed with air in a foam maker for onward
transmission to burning surface.

6.3 FOAM CONVEYING SYSTEMS
The system consists of an adequate water supply, supply of foam concentrate, suitable
proportioning equipment, a proper piping system, foam makers and discharge devices
designed to adequately distribute the foam over the hazard.
Conventional systems are of the open outlet type in which foam discharges from all outlets at
the same time, covering the entire hazard within the confines of the system. There are three
types of systems:
i) Fixed
ii) Semifixed
iii) Mobile
6.3.1 Fixed Foam System
Fixed foam conveying system comprises of fixed piping for water supply at adequate
pressure, foam concentrate tank, eductor, suitable proportioning equipment for drawing foam
concentrate and making foam solution, fixed piping system for onward conveying to foam
makers for making foam, vapour seal box, and foam pourer.
6.3.2 Semifixed Foam System
Semi-fixed foam system gets supply of foam solution through the mobile foam tender. A fixed
piping system connected to foam makers cum vapour seal box in case of cone roof tanks and
foam maker and foam pourers in the case of floating roof tanks conveys foam to the surface
of tank.
6.3.3 Mobile Foam System
Mobile system includes foam producing unit mounted on wheels which can be self propelled
or towed by a vehicle. These units supply foam through monitors/foam towers to the burning
surface.
6.3.4 However, certain other systems as follows are also available:
Sub-surface foam injection: This is a system for protection of fixed roof storage tanks. This
comprises of high back pressure foam generator and connected through product lines or
separate lines near the bottom of the tank.
Under the Seal Foam application:
This is a system for floating roof tank where the foam travels through a flexible pipe inside the
tank upto the center of the tank roof and exits at the seal rim of the floating roof precisely
where the fire is located thus rapidly flooding the rim seal area and quickly extinguishing the
fire.
Automatic Actuated Foam Flooding system:
In this system all the components and ingredients including premix solution are contained
within the system. Such systems usually have a premix solution supply tank pressurised by
air or inert gas. The automatic sensing of fire releases this pressure and places the system
into operation. The minimum requirement in design for the automatic actuated foam flooding
system is given in Annexure VII.

6.4 FLOATING ROOF TANK PROTECTION USING FOAM
6.4.1 Protection using Semi-Fixed Foam System:
For floating roof tank, foam shall be poured at the foam dam to blanket the roof’s rim seal.
Features of foam system for floating roof tank protection shall be as follows:
i) System shall be designed to create foam blanket on the burning surface in a reasonably
short period.
ii) Foam shall be applied to the burning hazard continuously at a rate high enough to
overcome the destructive effects of radiant heat.
iii) Foam makers/foam pourers shall be located not more than 24 M apart on the shell
perimeter based on 600 mm foam dam height. The height of foam dam shall be at least
51 mm above the top of metallic secondary seal.
iv) A minimum of two foam pourers shall be provided.
6.4.2 Protection using Automatic Actuated Foam Flooding system:

Provision of an automatic rim-seal protection system of foam flooding type shall be in line
with the details mentioned at 4.2.3 and at Annexure-VII.
6.5 FIXED ROOF TANK PROTECTION USING FOAM

Foam conveying system shall have same features as of floating roof tank excepting that a
vapour seal chamber is required before the foam discharge outlet.
Features of the foam system for fixed roof protection shall be as follows:
i) The vapour seal chamber shall be provided with an effective and durable seal, fragile
under low pressure, to prevent entrance of vapour into the foam conveying piping system.
ii) Where two or more vapour seal chambers are required these shall be equally spaced at
the periphery of the tank and each discharge outlet shall be sized to deliver foam at
approximately the same rate.
iii) Tanks should be provided with foam discharge outlets/ vapour seal chambers as
indicated below:
Tank Diameter in M. Minimum number of foam discharge outlet

upto 20 2
>20 upto 25 3
>25 upto 30 4
>30 upto 35 5
>35 upto 40 6
>40 upto 45 8
>45 upto 50 10
The estimation of number of foam discharge outlet is based on pourer capacity of 1000 Ipm at
2
a pressure of 7 kg/cm g upstream of eductor. This can be suitably adjusted for different
vapour seal chamber capacity in accordance with para 6.4 (iii).
6.6 FLOATING CUM FIXED ROOF TANK PROTECTION USING FOAM
Protection facilities shall be provided as required for fixed roof tank.

6.7 DYKE AREA/ SPILLS/ OIL SEPARATOR PROTECTION USING FOAM
Portable monitors/ Medium Expansion foam generator/ foam hose streams shall be
considered for fighting fires in dyke area, spills and oil separator.
6.8 FOAM APPLICATION RATE

The minimum delivery rate for primary protection based on the assumption that all the foam
reaches the area being protected shall be as indicated below. In determining total solution
flow requirements, potential foam losses from wind and other factors shall be considered.
For cone roof tanks containing liquid hydrocarbons, the foam solution delivery rate shall be at
least 5 Ipm/m2 of liquid surface area of the tank to be protected. For floating roof tanks
2
containing liquid hydrocarbons foam solution delivery rate shall be at least 12 Ipm/m of seal
area with foam dam height of 600 mm of the tank to be protected. In case of floating roof
2
sinking, the rate considered should be 8.1 Ipm/m of liquid surface areas.
6.9 DURATION OF FOAM DISCHARGE

The equipment shall be capable of providing primary protection at the specified delivery rates for
the following minimum period of time.
i) Tanks containing liquid hydrocarbons - Class 'C' Petroleum - 30 minutes.
ii) Tanks containing Class 'A' & 'B' Petroleum or liquids heated - 65 minutes.
above their flash points
iii) Where the system's primary purpose is for spill fire protection - 30 minutes.
6.10 FOAM QUANTITY REQUIREMENT
Calculation of foam compound storage should be based on the design criteria as per item 4.2.
The aggregate quantity of foam solution for a single largest tank fire should be calculated as
sum total indicated below under items (i), (ii) and (iii) for a minimum period of 65 minutes. The
quantity of foam compound required should be calculated based on 3% or 6% concentrate.
2
i) Foam solution application at the rate of 5 Ipm/m for the liquid surface of the single largest
2
cone roof tank or at the rate of 12 Ipm/m of rim seal area of the single largest floating roof
tank whichever is higher.
However, a foam solution application rate of 8.1 Ipm/m2 of the liquid surface of the largest
floating roof tank for 65 minutes shall be considered for a roof sinking case. (Refer
Annexure-VI for sample calculation)
ii) One portable foam monitor of 4500 Ipm foam solution capacity.
iii) Two hose streams of foam each with a capacity of 1140 Ipm of foam solution. A typical
example showing calculation of foam compound requirement is given at Annexure - II.
6.11 FOAM COMPOUND STORAGE

- Foam compound should be stored in containers of 20-30 Iitre capacity or 200 / 210 Iitre
capacity barrels in case of protein, fluoroprotein or AFFF. Foam compound can also be stored
in overhead storage tank of suitable capacity for quick filling of foam tender / nurser during
emergency.

- Type of foam compound used can be protein or fluoro-protein or AFFF. Alcohol Resistant
Foam can be used for specific application. Minimum of 90% of storage of foam compound
shall be of AFFF type. Minimum life of foam compound shall be taken as per manufacturer's
data.
- Foam compound should be tested periodically for ensuring its quality and the deteriorated
quantity replaced. The deteriorated foam compound can be used for fire training purposes.
- Quantity of foam compound equal to 100% of requirement as calculated in 6.11 should be

stored in the Installation, subjected to a minimum of 60,000 litres. However, for installations
having tankages larger than 60 M diameter, minimum of 77000 liters foam should be stored
(refer Annexure VI) or foam sufficient to fight two major fires whichever is more.
7.0 CLEAN AGENT BASED PROTECTION SYSTEM FOR CONTROL ROOM , SRR
AND COMPUTER ROOM PROTECTION
Selection of Clean Agent and system design for fire protection shall in line with the “Standard
on Clean Agent Fire Extinguishing Systems – NFPA Standard 2001 (latest edition). The
clean agent shall comply with the requirements of the “Ozone Depletion Substances
Regulation & Control Rules 2000, Ministry of Environment & Forests, Government of India.
QUANTITY AND STORAGE OF CLEAN AGENT

Each hazard area to be protected by the protection system shall have an independent
system.
The time needed to obtain the gas for replacement to restore the systems shall be
considered as a governing factor in determining the reserve supply needed. 100% standby
charge of clean agent containers shall be considered for each protected hazard.
Storage containers shall be located as near as possible to hazard area but shall not be
exposed to fire.
Storage containers shall be carefully located so that they are not subjected to mechanical,
chemical or other damage.
All the components of the system shall be capable of withstanding heat of fire and severe
weather conditions.
8.0 CARBON DIOXIDE SYSTEMS
Fixed CO2 systems shall be provided in Turbo generator enclosure, Gas turbine enclosure etc
as per OISD STD 173. Fixed CO2 system should be designed and installed in accordance
with NFPA-12.
Before the CO2 flooding system is operated; persons in the confined area should be
evacuated.
Carbon dioxide is an odourless and colourless inert gas having a proven fire extinguishing
property. When applied in a proper manner and in proper quantities on a fire hazard, it
extinguishes fire by cutting off the oxygen and creating an inert atmosphere around the
hazard. If the inert atmosphere is maintained for a reasonable time the possibility of flash
back also is reduced.
Carbon dioxide is best applied to a fire hazard through a fixed system consisting of CO2
storage, distribution piping and discharge nozzles.

9.0 DRY CHEMICAL EXTINGUIS-HING SYSTEM
The extinguishing system comprises of supplying the Dry Chemical agent, manually or
automatically, through a distribution system onto or into the protected hazard.
9.1 RECOMMENDED USE:
Dry chemical powder extinguishing system can effectively be used on following hazards.
- Electrical hazard such as transformers or oil circuit breakers.
- Combustible solids having burning characteristic like naphthalene or pit which melts while
on fire.
- Class 'A','B','C' & 'D' fire using multipurpose dry chemical. Requirement for each item
should be finalised while deciding design basis.
9.2 SYSTEM DESIGN:
Basic requirement of designing the dry chemical extinguishing system is to provide for
sufficient quantity and rate of discharge depending upon the hazard.
System consists of dry chemical powder and expellant gas container assemblies of capacity
sufficient for given hazard with distribution piping and discharge nozzles. System can be
actuated manually or automatically on visual or automatic means of detection. Alarm and
indication shall be provided to show that the system has operated and personnel response is
needed.
Personnel safety shall include training, warning signs, discharge alarm, respiratory protection
and prompt evacuation of personnel.
Following types of systems can be provided to protect a hazard:
a. Total flooding system
b. Local application system
c. Hand hose line system, and
d. `Pre-engineered system
(Refer NFPA-17 for limitations & precautions for use of dry chemical and for system design)
10.0 Modernization plan for fire fighting equipments:
Rapid intervention, Water Mist cum Compressed air Foam Technology
The technology of water mist cum compressed air foam system involves creation of water mist
or a mist combination of water and foam using specialized nozzles. The mist droplets create an
enlarged surface area resulting in rapid cooling due to absorption of heat. Mist droplets turn to
steam on contact with fire resulting in blanketing effect, thereby cutting off oxygen &
extinguishing the fire very fast. This is achieved by propelling mixture of water & foam using

compressed air.
Water mist cum Compressed air foam system is for low as well as high pressure rating. The
suitability of the system shall be decided for the particular application based on minimum recoil
jerk, safety of the user and refillability criteria. The system shall be approved as per highest
international safety standard DIN EN3 or equivalent for maximum fire rating.
The water mist cum compressed air foam system has advantage over conventional fire fighting
systems (DCP, CO2) as it provides combined effect of cooling & blanketing which results in
efficient fire fighting thereby helping control fire in the initial stages. Mist also helps in blocking
radiant heat making it easier for the fire fighter to approach the fire.
In addition to the conventional fire extinguishing systems such as foam, carbon-dioxide and
DCP, the Back pack/Portable/Trolley mounted (mobile) water mist cum compressed air foam
technology should be used to fight fires at critical locations such as hot pumps handling fluids
above auto ignition temperature, like column bottom pumps at CDU, VDU, Coker, FCCU &
HCU units, any other high temperature column, exchangers etc. Criteria to determine the
quantity is given in the following table.
11.0 FIRST AID FIRE FIGHTING & Other EQUIPMENT
11.1 Criteria to determine the quantity needed:
Portable fire fighting equipment shall be provided in Refinery/Process plant as indicated in the
following table:

Description Norms/criteria to determine the quantity needed

Conventional fire fighting equipments
i) Dry chemical powder While selecting the Extinguisher, due consideration should be
(DCP)* fire extinguishers - given on the factors like flow rate, discharge time and throw in
10 kg capacity: IS:15683/ line with IS: 2190 / UL711.
UL299 Extinguisher to be located in process units, pump houses, pump
area, LPG storage area, LPG bottling plant, Oil separator, tank
truck/ tank wagon loading areas, substations, Work shops,
laboratory, power station buildings etc.
The number should be determined based on the max. Traveling
distance of 15 M in above areas. At least one fire extinguisher
2
shall be provided for every 250 m of hazardous operating area.
There shall be not less than two extinguishers at one designated
location e.g. pump house.
ii) Dry chemical powder fire The extinguishers with the selection criteria viz. flow rate,
extinguishers 25/50/75 kg discharge time and throw mentioned as above, to be located in
capacity: IS:10658/ UL299 critical operating areas.
(in addition to 10kg DCP At least one fire extinguisher should be provided for every 750 m2
requirement) of hazardous operating area.
iii) CO2 extinguishers To be located in substations, power stations, office building and
4.5/6.5/9.0/22.5 kg capacity control room. The number should be determined based on the
(IS:2878/UL154) maximum traveling distance of 15 metre.
At least one fire extinguisher shall be provided for every 250 m2
of hazardous operating area. There shall not be less than 2nos.
extinguishers at one designated location e.g. control room.
iv)Portable clean agent This should be as an alternate to CO2 extinguisher.
extinguishers To be located in control rooms, computer rooms, laboratories
and office buildings.
v) Portable water-cum-foam Minimum 2 no. for Petroleum refinery and 1 no. for Gas
monitor. Processing Plant
vi) Steam lancers(as a part of For fighting incipient fires at flange leakages & hot pumps.
utility station)
vii) Rubber hose reel (25mm) To be located in Process unit battery limits and other process
areas for quenching of incipient fires.
Modernization plan for fire fighting equipments
viii)Rapid intervention, Water
Mist cum Compressed air In addition to the conventional fire extinguishing systems such as
Foam Technology: foam, carbon-dioxide and DCP, Minimum of one trolley type
should be provided as an alternate to existing DCP system at each
Filling capacity 35 to 50 litres
critical locations such as hot pumps handling fluids above auto
for trolley mounted & 9 litres
ignition temperature, like column bottom pumps at CDU, VDU,
for backpack system. The
Coker, FCCU & HCU units and minimum one back pack at critical
system shall be approved as
high temperature column & exchangers in these units.
per highest international
safety standard DIN EN3 or
equivalent for maximum fire
rating.
Note : 1) In place of 10 kg, 5 Kg DCP Extinguisher shall be provided at elevated locations.
2) For substations, power station; the number and area for placement of extinguishers
should be decided as per OISD STD-173 requirements.

11.2 Other fire fighting Equipment:

Additionally, following items should also be provided. The number of units required for these shall be
decided by local management, on case-to-case basis.
i) Thermal imaging Camera: As an aid to the fireman during fire fighting operation to locate the seat
of the fire and to facilitate search and rescue operation in smoky area e.g. during cable gallery.
ii) Personal Protective Equipment required during Fire Fighting like Water gel based blanket, Fire
Proximity Suit, Self contained breathing apparatus, Air line breathing apparatus, Safety Helmets,
Fire Helmets, Stretcher, First Aid box, Rubber hand gloves, canister mask etc.
iii) Other Equipments like Portable Gas detectors, Explosive meter, Oxygen meter, Hand operated
siren, Red/Green Flag for fire drill, Safe walk roof top ladder, emergency lighting, portable mega
phone, various leak plugging gadgets, oil dispersants and oil adsorbents, lifting jacks (for rescue
of trapped workers), etc.
Note: The number of unit required for these should be decided by local management, on case to case
basis.
12.0 MOBILE FIRE FIGHTING EQUIPMENT
12.1 Fire Tenders:
The exact number of fire tenders shall be higher of the items (a) or (b):
(a) The quantities firmed up in each case based on two simultaneous major fires taking into
consideration the size, location of the plant and statutory requirements.
(b) The quantities indicated below.
i) 3 nos. of foam tenders out of which two are for fire fighting one for spill/ standby. The foam
tender should have foam tank capacity of 3000/3600 Iitre and the pump capacity of
minimum 4000 Ipm at 8.5 kg/cm2.
ii) One DCP tender having 2 vessels of 2000 kg capacity each with Nitrogen as expellant gas.
These are required for fighting LPG/Gas fires.
A monitor should have a variable throw of 15/25/40 kg/sec. The throw of the monitor shall be
40 to 50 M for the DCP charge.
12.2 Other Mobile Equipment
In addition to fixed monitors provided in the tank farm, following additional mobile equipments
shall be provided:
i) Minimum 2 nos. of foam tank trailers with field adjustable variable flow water cum foam
monitors having foam tank capacity of 500-1000 liters and monitors capacity of minimum 1000
GPM and UL/FM listed / approved.
ii) Minimum 2 nos. of Trolley mounted water cum foam monitors of capacity of minimum 2000
GPM with field adjustable variable flow and UL/FM listed / approved. Foam induction to the
monitor shall be possible from minimum 60M distance from the monitor.
iii) 1 to 2 numbers of Foam Nurser (i.e. Trailer mounted foam compound supply tank) with foam

compound tank of 7000 – 16000 litre capacity with suitable pump for foam transfer.
iv) 1 to 2 nos. of portable/ trailer fire pumps of capacity ranging from 1800 to 2250 Ipm at
discharge pressure of 7 kg/cm2 g.
12.3 Other Fire Fighting Equipment

Following other fire fighting equipments shall be provided:
i) Emergency rescue equipment like cutters, expanders, inflatable lifting bags, leak pads,
protective clothing, breathing apparatus, trolley mounted BA set
ii) Fire Hoses: IS 636: Type A or Synthetic hose of Type B.
The hose length shall be calculated as follows:
i) For installation with hydrants upto 100 Nos: - One 15 mtrs hose length/hydrant.
ii) For installation with more than 100 hydrants:

- One 15 metre hose length/hydrant, for the first 100 hydrants; and,
- One 15 M hose length for every 10 hydrants above 100.
The hose length so calculated shall be suitably divided into hose lengths of 15 M, 22.5 M or 30
M. Of the total requirement of the hoses, minimum 50% of hoses shall be of type B.
iii) Fire jeep (s) with two way radio communication facility and towing facility.
iv) One ambulance fitted with medical aid and suitable arrangements.
v) Other accessories, foam making branch pipes, nozzles, etc. as per requirements.
vi) 4" Hoses of suitable length for feeding to large capacity monitors wherever installed.
In addition to above, provision of following equipment should also be considered:
i) Suitable equipment for fighting high level fires.
ii) Multipurpose fire fighting skid should be used as a single self sufficient unit of having capacity
of discharging foam, water/ water mist & DCP and thus performing multiple functions
effectively, individually or together, saving power and time in combating a fire. Such a
Multipurpose fire fighting skid should be used in lieu of one foam tender/ DCP tender as
described in 10.1(b)-(i).
Broad specifications of the fire fighting equipment listed above are given in Annexure-lll.
13.0 STORAGE OF FIRE FIGHTING AGENTS
The following quantities of fire fighting agents shall be stored in the Refinery as given below in the
table.

S. Description Quantity to be stored

No
i) Dry chemical powder: Reaction product 4000 kg for the DCP tender plus 500 kg
of urea and Potassium bicarbonate i.e. for additional requirement. This is in
Potassium Carbamate or Potassium addition to the charge loaded on tender.
Allophonate base - as spare charge for
the DCP tender/Trolleys. The DCP
product should be UL listed.
While selecting the dry chemical
powder, due consideration should be
given to the typical properties viz.
Apparent Density (0.65 +/- 0.05), Fire
Rating (144B), Thermal Gravimetric
Analysis (with decomposition at around
250oC) and foam compatibility.
ii) Siliconised Potassium bicarbonate DCP As required based on shelf life. However,
powder (IS 4308:2003/UL listed) / Mono- minimum 10% of the total charge in the
ammonium phosphate based DCP extinguishers should be maintained.
powder (IS: 14609/UL listed) for
recharging of fire extinguishers.
iii) Foam compound: (IS: 4989 (Part-III) / Higher of the quantities in :
UL listed (UL-162) 1. 60,000 litre (excluding that in foam
tender) for installation having largest
tank of diameter as 60 M.
2. 77,000 litre (excluding that in foam
tender) for installation having largest
tank of diameter as 79 M. Or, (as
calculated in 6.11).
3. In the installation where the largest
tank diameter is less than 60 M,
foam quantity requirement (excluding
that in foam tender) shall be
calculated as per 4.4.11 of OISD-
STD-117.
(Refer Annexure- II and Annexure-VI for
typical calculation for foam requirement)

14.0 DETECTION SYSTEM AND ALARM
Human beings are excellent fire detectors since they possess sense of smell, sight, and touch.
But since human senses are also unreliable due to the need for frequent rest and relaxation, a
number of mechanical, electrical and electronic devices have been developed to mimic human
senses in the detection of gases / smoke / heat and flame.
A flammable gas detector is designed to give a warning of the presence of flammable gases or
vapours in air, well before they reach explosive concentrations. Normally, the detector
provides visible and audible alarm signals, but frequently it performs a further function by initiating
control action such as increasing ventilation or shutting off the source of gas. A flammable gas
detector can also be used for tracing leaks and checking that vessels or tunnels are gas free
before entering.
14.1 AREAS TO BE COVERED WITH DETECTORS
14.1.1 The following areas shall be provided with hydrocarbon gas detectors:
- Light hydrocarbon pumps in process units.

- Process cooling tower top platform in the units having pressurised cooling water return.
- Fuel gas knock out drum
- Suction side of forced draft air blowers if located where hydrocarbon vapours can be
present.
- Light hydrocarbon pump stations if located below grade level.
- LPG Horton spheres
- LPG pump house
- LPG bulk truck loading area
- LPG bulk wagon loading area
- LPG bottling, storage, repair sheds.
- Gas compressor
- Air-intake point for control room, in line with OISD-STD-163.
The exact location and number of points should be decided on need basis.
14.1.2 Following areas shall be provided with Smoke/ Flame / Heat detectors with alarm and/or system to
actuate relevant fire suppression system:
- LPG spheres
- LPG filling sheds
- LPG pumps/compressors
- LPG loading/unloading, both in tank truck and tank wagon gantry
14.1.3 Hydrocarbon detectors shall be installed near all potential leak source of class-A e.g. tank dykes,

tank manifolds, pump house manifold etc.
Hydrocarbon detector of proper type shall be selected and also shall be proof tested and shall
be maintained in good condition.
14.1.4 Additionally, following areas should also be provided with suitable detectors:
- Extremely hazardous area in process units
- Computer room, Server room, Process control rooms, Record room
- Unmanned electric substations / MCC rooms
- Cable galleries
- Chemical Storage
15.0 COMMUNICATION SYSTEM
Effective communication is an essential element in the fire protection system of any plant. The
following communication systems should be provided in the Refinery/Process plants.
i) TELEPHONE
Fire Station Control Room shall be provided with 2 nos. of internal telephones which are
exclusively meant for receiving fire/emergency calls only. These phones should have facilities for
incoming calls only. For general communication a separate telephone should be provided.
Fire Station should also have a direct P&T telephone. Hot line, telephone for contacting mutual
aid parties shall be provided wherever possible.
ii) PUBLIC ADDRESS SYSTEM
Public address system should be connected to all control rooms, administration building (all
floors), all departmental heads, security etc. Telephone exchange should control and take care of
this system.
iii) A.R.P. (AIR RAID PROTECTION) SYSTEM / PAGING
Air raid communication system (with civil defence) should be provided in the control room of fire
station. The details of such a system should be worked out in association with civil defence
authorities of the area.
Alternatively, group communication system (all call system)/ alpha numerical pager system
should be considered for group emergency communication.
iv) FIRE SIRENS
The Fire siren/s should be located suitably to cover the whole area with the operational control in
the Fire station control room. These should be tested at least once in a week to keep them in
working condition.
Fire siren code should be as follows:
1. SMALL FIRE: No siren


2. MAJOR FIRE: A wailing siren for two minutes.
3. DISASTER: Same type of siren as in case of Major Fire but the same will be sounded for three
times at the interval of one minutes i.e.( wailing siren 2min + gap 1 min + wailing siren 2min + gap
1min + wailing siren 2min) total duration of Disaster siren to be eight minutes.
4. ALL CLEAR (For fire): Straight run siren for two minutes.
5. TEST: Straight run siren for two minutes at frequency atleast once a week.
v) WALKIE-TALKIE / WIRELESS
All the Fire Tenders shall be provided with a walkie-talkie/ wireless system which will help in
communicating with the people in case the other system fails. Besides, key personnel co-
ordinating emergency operations should also be provided with walkie-talkie.
vi) FIRE ALARM SYSTEM
The fire alarm systems includes manual call points (break glass), automatic gas/smoke/heat
detectors, release & inhibit switches for fire suppressing clean agent and conventional or micro-
processor based data gathering panels viz. central fire alarm panel, mimic panels & associated
equipments.
Manual Call Points shall be provided at suitable locations like access point, approach roads,
walkways etc. to cover the critical areas. These manual call points activate the audio-visual
alarm in the Central fire alarm panel installed in fire station and in the repeater panel installed in
the respective area control room(s). The location of these points shall be conspicuously marked
on the annunciation panel for proper identification. These manual call points should also have
suitably wired telephone handset to facilitate communication with respective area control room
and fire station.
16.0 INSPECTION & TESTING OF FIRE PROTECTION SYSTEM:

The fire protection equipment shall be kept in good operating condition all the time and the fire
fighting system shall be periodically tested for proper functioning and logged for record and
corrective actions. In addition to routine daily checks/maintenance, the following periodic
inspection/testing shall be ensured.
16.1 FIRE WATER TANK/RESERVOIR /Foam Tanks
i) Above ground fire water tanks should be inspected externally & internally as per OISD-STD-129.
ii) The water reservoir shall be emptied out & cleaned once in 3 years. However, floating leaves,
material or algae, if any shall be removed once in 6 months or as & when required.
iii) The foam tanks shall be inspected every 3 years externally and shall undergo internal inspection
every 10 years.
16.2 FIRE WATER PUMPS
i) Every pump should be tested by running it minimum two times a week.

ii) Once a month each pump should be checked for the shut off pressure and auto start operation.

Observations should be logged.
iii) Once in six months each pump shall be checked for performance. This can be done by opening
required number of hydrants/monitors depending on the capacity of the pump and by verifying
that the discharge pressure, flow and the motor load are in conformance with the design
parameters. For flow measurement suitable devices like ultrasonic instrument can be considered.
16.3 FIRE WATER RING MAIN
The ring main should be checked once a year for leaks etc. by operating one or more pumps with
the hydrant points kept closed as required to get the maximum operating pressure.
The ring main, hydrants, monitors, valves should be visually inspected every month for any
pilferage, defects and damage.
All fire main valves should be checked for operation and lubricated once in six months for fresh
water and once in three months for saline/ETP water.
Thickness survey & inspection of Firewater header should be done once in three years.
Segment - wise flushing of main header should be done once a year.
16.4 FIRE WATER SPRAY SYSTEM

Fixed water cooling spray systems on storage tanks should be tested at least once in six months.
Deluge systems on LPG spheres and bullets should be tested at least once in every three
months, for proper performance.
Spray system in LPG bottling plant and should be tested at least once in every quarter. Operation
of ROVs should be checked once in three months.
16.5 FIXED / SEMI-FIXED FOAM SYSTEM

Foam system on storage tanks should be tested once in 12 months. This shall include the testing
of foam maker/ chamber.
The foam chamber should be designed suitably to facilitate testing of foam discharge outside the
cone roof tank.
Piping should be flushed with water after testing foam system.
Thickness survey & inspection of Foam system piping should be done as per OISD STD 142.
16.6 CLEAN AGENT (HALON SUBSTITUTE) BASED EXTINGUISHING SYSTEM
The systems should be checked as given below:
a) Agent quantity and pressure of refillable containers should be checked, six monthly.
b) The complete System should be inspected for proper operation once every year (Refer latest
NFPA Standard 2001 (latest edition) for details of inspection of various systems).
16.7 MOBILE FIRE FIGHTING EQUIPMENT AND ACCESSORIES

Foam tenders should be tested at least once a week. This should include running of pump and
foam generation equipment.
All other mobile equipment should be checked, serviced and periodically tested under operating
conditions, at least once a month.

Trailer mounted pumps should be test run at least once a week.

All the fire hoses should be hydraulically tested at least once in six months.
DCP tender should be visually inspected every week. This should include checking of expelled
gas.
Records shall be maintained of all maintenance, testing and remedial/ corrective actions taken
wherever necessary.
16.8 DCP/ CO2/ FOAM TYPE FIRE EXTINGUISHERS:
Inspection and testing frequency and procedure should be in line with OISD-STD-142.
16.9 COMMUNICATION SYSTEM
Fire sirens should be tested at least once a week. Testing of Manual call points once in a month,
walkie-talkies every week and other communication systems covered under item 13.0 should be
done as per manufacturer’s guidelines.
16.10 DETECTORS
The operability of all types of detectors should be tested once in every three months. Calibration
of gas detectors using test gas should be done once in every six months or as per manufacturer's
specification whichever is earlier.
17.0 FIRE FIGHTING ORGANISATION
A full-fledged fire fighting organisation shall be provided. A typical organisation for the fire and
safety department for a large size, Refinery/Gas Process Plant is given below:
D G M /C H IE F M A N A G E R
F IR E & S A F E T Y
S R M G R /M A N A G E R S R M A N A G E R ./
( F IR E P R O T E C T IO N ) M A N A G E R (S A F E T Y )
M G R /D Y .M G R ./ M G R /D Y .M G R / S A FE T Y
S R .F IR E O F F IC E R S R . O F F IC E R O F F IC E R
(F IR E M A IN T .) (O P E R A T IO N S )
E A C H S H I F T S R . F IR E O F F IC E R & F IR E
O P E R A T O R S

The Fire Protection / Fighting organisation shall be manned by personnel having suitable
professional qualification & training. For ease of identification of the fire fighters, the crew
members should be provided separate uniform.
18.0 FIRE PROTECTION TRAINING

All the plant personnel shall be trained on fire prevention and fire fighting aspects. Fire fighting skill
upgradation / refresher training shall be given periodically. The fire crew belonging to the fire
fighting department shall be given intensive training for the use of all equipment and in various fire
fighting methods for handling different types of fires.
Regular contractors and security personnel shall be given safety, fire Fighting and rescue
operation Training through oil industry approved reputed institute and record maintained.
A fire training ground with the following minimum training facilities should be set up:
a) Trench fire simulation facilities

b) A small open top tank fire simulation facility
c) Pan fire simulation facility.
d) Pipeline flange leak fire simulation facility
e) Fire suits and breathing apparatus.
A mock fire drill should be conducted once in a month to rehearse the fire emergency procedure
and to keep the fire fighting team trained and alert and facilities in top order.
A layout of typical fire training ground and a brief write up on the facilities in the training ground are
given in Annexure-IV.
For refineries & Gas Processing Plants not equipped with adequate fire training facilities; skill up
gradation/ refresher training shall be periodically conducted at reputed institutes having live
module fire fighting training facilities.
19.0 MUTUAL AID
Refineries/process plants should have written mutual aid agreements with similar neighbouring
industries fully detailing the responsibilities of the members of the scheme, the procedures to be
adopted, the minimum number of equipment and manpower and minimum quantity of
consumables to be exchanged/loaned. A model agreement of mutual aid is given in Annexure - V.
A chart showing mutual aid arrangement shall be exhibited prominently at least in fire station and
Disaster Control Room.
20.0 FIRE EMERGENCY PROCEDURES
Each installation shall prepare a detailed "Fire emergency procedures" manual outlining the
actions to be taken by each personnel during a major incident for use by the organization and this
manual shall be available to all personnel in the installation.
The fire emergency procedures including fire fighting plan should be prepared for fighting fires in

the process units, in and around tanks, in the LPG storage and bottling plants, product loading
gantries, separators, electrical fire, warehouse and building fires etc.
21.0 FIRE STATION / CONTROL ROOM

Fire Station Control Room is of critical importance as it is main coordinating centre between the
emergency site and response crew. Important activities of control room are communication,
mobilisation, up-keeping and maintenance. The location and construction of control room
should therefore be suitable for these activities.
21.1 LOCATION
Fire station should be located at minimum risk area. It should be spaced at a safe distance from
any process plant and other hazardous areas. For details refer OISD-STD-118.
When planning for new fire station, adequate land should be provided for parking and
maneuvering of fire appliances. Also, access and exits of the building should not be obstructed by
other vehicles.
Fire station control room should be close to parking bay for fire appliances and should have good
view of vehicles parked.
Additional Fire-post should be considered during the expansion for improving the response time.
21.2 COMMUNICATION:
Reliable communication system is must for supporting effective fire service dept. operations.
Following equipment must be available in the Control Room, (i) Telephones (2) Wireless sets/
walkie-talkie (with a dedicated frequency) (3) Hotlines to neighbouring industries/civil Fire Brigade
(4) Fire Alarm system with central control in fire station.
21.3 GENERAL:
a) Fire Station should have 2 overhead storage tanks for foam compound storage, so that during
emergency refilling is not delayed.
b) Control room should have portable emergency lights.
c) Fire Station should have prominently located pressure gauge showing fire water network
pressure.
d) Emergency power supply shall be ensured for Fire Station & Fire water Pump House.
22.0 PASSIVE FIRE PROTECTION MEASURES / OTHER SAFETY MEASURES
Although adequate fire protection is provided in an installation, Passive fire protection measures
as indicated below should be adopted wherever required.
a) Fire Proofing of structural members

b) Spark Arresters and Flame Arresters
c) Fire Separation Walls in concealed space/Electrical Substation/ transformer yard/ bays/
cable galleries.
d) Fire Seals in underground sewer system / Flare Knock out Drums

e) Impounding Basins/Dyke Walls

f) Lightning Arresters
g) Pressurisation of Enclosure
h) Venting Facilities of process equipment
i) Electrical Relays and Fuses, earth leakage circuit breakers, neutral current circuit breaker
j) Fire retardant coatings and tapes for cables
k) Fire resistant low smoke insulation cable.
l) Flame proof and flame resistant electrical enclosure.
m) Insulation of hot surfaces.
23.0 FIRE PROTECTION SYSTEM AUDIT
In view of continuous expansion and additions in refineries, the system should be internally audited
once in 3 years for compliance of OISD standards and statutory requirements
24.0 REFERENCES
1) NFPA-11 Standard For Low Expansion Foam Systems
2) NFPA 11-A Standard For Medium & High Expansion Foam Systems
3) NFPA 13 Standard For The Installation Of Sprinkler Systems
4) NFPA 15 Standard For Installation Of Water Spray Systems
5) NFPA 17 DCP System
6) NFPA 20 Standard For Installation Of Centrifugal Fire Pumps
7) NFPA-2001 Standard For Clean Fire Extinguishing System
8) API - 2001 Fire Protection In Refineries
9) Petroleum Rules -2002
10) Fire Protection Manual (Part-II) Of TAC
11) TAC Building Regulations
12) TAC Regulations For Electrical Equipment Of Buildings
13) Model Code Of Safe Practices - The Institute Of Petroleum (U. K. )
14) International Safe Practices Of Oil Industry
15) IS:3844- Code Of Practice For Installation Of Internal Fire Hydrants In Multistorey Building
16) OISD-STD-142 Inspection Of Fire Fighting Equipment & Systems
17) OISD-STD-154 Safety Aspects In Functional Training

18) Ozone Depletion Substances Regulation & Control Rules 2000, Ministry of Environment & Forests,
Government of India
19) IS-15683: Portable Fire Extinguishers - Performance and Construction - Specification
20) IS:14609 : Dry Chemical Powder for fighting A,B,C Class Fires - Specification
21) UL154: Carbon-Dioxide Fire Extinguishers
22) UL299:Dry Chemical Fire Extinguishers
23) UL711:Rating & Fire Testing of Fire Extinguishers

ANNEXURE-1
EXAMPLE FOR CALCULATION OF FIRE WATER FLOW RATENote1
1. DESIGN BASIS
The fire water system in an installation shall be designed to meet the fire water flow requirement
to fight two major fires simultaneously.
2. FIRE WATER DEMAND
Various areas which can be under fire shall be considered and fire water demand for each area
shall be calculated based on design basis, as indicated below:
2.1 FLOATING ROOF TANKS PROTECTION
a) Data:
Total storage capacity in one dyke area = 1,20,000 m3
No. of tanks = 2
Capacity of each tank = 60,000 m3
Diameter of each tank = 79 m
Height of each tank = 14.4 m
b) Cooling water requirement:

Cooling water rate @ 3 lpm/ m2 of tank shell area for tank on fire,
Cooling water required = (π x 79 x 14.4 x 3) lpm
= 10,726 lpm
= 644 m3/hr
Assuming that second tank is located within the tank dyke at a distance more than 30 meters
from the tank shell.
Therefore, in such case cooling water required at the rate of 1 lpm/ m2 of tank shell area shall be
215 m3/hr.
Total cooling water = 859 m3/hr
c) Foam water requirement for rim seal area:

Water flow required for applying foam on a largest tank burning surface area.
For floating roof tank of 79 m diameter,
Diameter of the tank (D1) = 79 m
Distance of foam dam from shell = 0.8 m
Diameter of roof up to foam dam (D2) = 79- (2 x 0.8) = 77.4 m
the rim seal area = ((π /4) x (792 - 77.42)) m2
= 197 m2
2
Foam solution rate @ 12 lpm/ m = 2,364 lpm
(For 3% foam concentrate) = (0.97 x 2364) lpm
= 2293 lpm.
= 2293 x 60 m³/hr
1000
= 138 m³/hr.

Note-1: These are sample calculations only. Calculations on the basis of actual site conditions and dimensions need to be carried
out for each installation as per guidelines provided in clause 5.2.
d) Fire water for supplementary hose stream based on 4 hydrant streams + 1 High Volume Long
Range water monitor.
3 3 3
4 x 36 m /hr + 1 x 228 m /hr = 372 m /hr
e) Total water required:

Tank cooling 859 m3/hr
3
Foam application 138 m /hr
Supplementary stream 372 m3/hr
Total 1369 m3/hr
2.2 CONE ROOF TANKS PROTECTION
a) Data:
Total storage capacity = 50,000 m3
No. of tanks = 4 with 12,500 m3 capacity each.
Diameter of each tank = 37.5 m
Height of each tank = 12 m

Cooling water rate = 3 lpm/ m2 of tank shell area for tank-on-fire
Cooling water required = π x 37.5 x 12 x 3
= 4243 lpm
= 255 m3/hr
Cooling water required for other tanks at the rate of 3 lpm/ m2 of shell area for tanks falling
within (R+30) metre from centre of tank on fire,
= 3 x 255 m3/hr
= 765 m3/hr
Total cooling water rate = (255 + 765) m3/hr
3
= 1020 m /hr
c) Foam water requirement (for 1 tank only) @ 5 lpm/ m2,

Foam solution rate = (π x (37.5)2 x 5) lpm
4
= 5525 lpm
For 3% foam concentration = (5525 x 0.97) lpm
= 5359 lpm
3
= 322 m /hr
d) Fire water for supplementary hose stream = 372 m3/hr
e) Total water required :


3
Foam application 322 m /hr
Supplementary stream (including 2 HVLR) 372 m3/hr
3
Total 1,714 m /hr
2.3 LPG SPHERES AREA PROTECTION

a) Data:
No. of sphere in one area = 3
Diameter of each sphere = 17 m

water rate for cooling = (π x172 x 10.2) lpm
= 9,265 lpm
= 556 m3/hr
Considering other 2 spheres located within = (3 x 556) m3/hr
(R+30) M from centre of sphere and fire
cooling water rate for 3 spheres
= 1668 m3/hr
c) Hose stream requirement (including 1 HVLR) = 372 m3/hr
d) Total water requirement = 2040 m3/hr
2.4 LPG RAIL WAGON LOADING GANTRY PROTECTION
a) Data:
Total No. of loading points = Conventional or BTPN.
Width of Tank wagon gantry = 12 m

Divide total area of gantry into equal segments such that each segment measuring 15 m X 12
m and consider 3 segments operating at a time.
Water rate required = (3 x 15 x 12 x10.2) lpm

= 5508 lpm ‘
= 330 m3/hr
Water Requirement for supplementary Hose:
Water for 4 single hydrant streams = 4 x 36 = 144 m3/hr.
Water for 1 monitor stream (HVLR) = 1x 228 = 228 m3/hr.
Total water requirement = 372 m3 / hr.
Total water flow rate for gantry protection

(a) Gantry cooling = 330 m³/hr.
(b) Supplementary hose requirement = 372 m3/ hr
Total = 702 m³/hr.

2.5 PROCESS UNIT PROTECTION

For process unit protection in case of fire, water is to be applied using fixed water monitors and
hose lines. Unit blocks separation is by 30 metre. Three following alternatives are considered for
fire water rate.
Alternate-I
Total unit area = 120 x 80 m2
Consider water rate @ 1 lpm/ m2 on area basis,
Water rate = (9600 x 1) lpm
= 576 m3/hr
Water for supplementary hose stream (including 1 HVLR) = 372 m3/hr
Total water rate = 948 m3/hr
Alternative - II
Consider a 10m x 10m portion of process unit area on fire. Provide water cover over an area of
30m x 30m at the rate of 10.2 lpm/ m2,
Water rate = (900x10.2) lpm
= 9180 lpm
= 551 m3/hr
Water for supplementary hose steam (including 1 HVLR) = 372 m3/hr
Total water rate = 923 m3/hr
Alternate – III
Water required for portion of unit area provided with fixed spray system (Extreme Hazardous
Area)
Area assumed = 1000 m2
Water rate = 10.2 lpm/ m2
Cooling water required = 10200 lpm
= 612 m3/hr
Water for supplementary hose stream (including 1 HVLR) = 372 m3/hr
Total cooling water required = 984 m3/hr
Considering the maximum water under alternative I, II & III

3
Design flow rate = 984 m /hr
2.6 Fire water calculation for full surface fire on largest floating roof tank (roof sinking case) –
Treated as a single contingency
a) Data:
Total storage capacity in one dyke area = 120,000 m3
No. of tanks = 2
3
Capacity of each tank = 60,000 m


2
Cooling water rate @ 3 lpm/ m of tank shell area for tank-on-fire
Cooling water required = π x 79 x 14.4 x 3
= 10726 lpm
= 644 m3/hr
Assuming that second tank is located within the tank dyke at a distance more than 30M from
the tank shell.
Then, cooling water requirement @ 1 lpm/ m2 of tank shell area shall be 215 m3/hr.
Total cooling water = (644 + 215) m3/hr

= 859 m3/hr
c) Water requirement in foam application

Foam Application Rate : 8.1 lpm
Foam Solution Requirement = ((π x 79 x 79) / 4 x 8.1) lpm

= 39720 lpm
= 2383 m3/hr
Water required for the foam solution = 97% x 2383 m3/hr
= 2312 m3/hr …… refer Note-2
d) Fire water for supplementary hose stream based on 4 hydrant streams + 1 High Volume Long
Range water monitor.
4x36 m3/hr + 1X228 m3/hr = 372 m3/hr
e) Total water required:

Foam application 2312 m3/hr (Plus requirement for foam losses as per Note-2)
Supplementary stream 372 m3/hr
3
Total 3543 m /hr
3
Say Total water requirement = 3550 m /hr (Plus requirement for foam losses as per Note-2)
3.0 TOTAL DESIGN FIRE WATER RATE
For two major fire fought simultaneously

Fire water rates for 5 cases are given below:
i) Floating roof tank protection = 1369 m3/hr

3
ii) Cone roof tank protection = 1714 m /hr
iii) LPG sphere protection = 2040 m3/hr
iv) LPG rail wagon loading gantry = 702 m3/hr
Protection

3
v) Process unit protection = 984 m /hr
Note-2: Potential foam losses from wind and other sources to be added to this value as per design requirements. These losses are
not considered in this typical calculation sheet.
3.1 For fighting the above two major fires simultaneously, the design firewater rate is the sum of the
two highest water rates i.e.
Design fire water rate = 2040 m3/hr + 1714 m3/hr
= 3754 m3/hr
Say = 3750 m3/hr
3.2 For full surface fire of largest floating roof tank (Roof sinking case):
Total firewater flow rate required as per typical calculations shown at 2.6 is 3550 m3/hr. (Plus
requirement for foam losses as per Note-2)
The design Firewater rate shall be highest of above 3.1 or 3.2.
NOTE:
Full surface fire of a floating roof tank roof sinking case being a remote possibility, it is
considered as a single largest contingency for the purpose of arriving at design fire water
requirement.
Note-2: Potential foam losses from wind and other sources to be added to this value as per design requirements. These losses are
not considered in this typical calculation sheet.

ANNEXURE - II
EXAMPLE FOR CALCULATION OF FOAM COMPOUND REQUIREMENT
1. CONE ROOF TANK PROTECTION:
i) Data :
3
Total Storage capacity in one dyke area = 50000 m
Number of tanks = 4
Diameter of each tank = 37.5 m
Height of each tank = 12 m
ii) The quantity of foam compound shall be calculated as follows:
Consider foam solution application @ 5 lpm/ m2 for the liquid surface of the single largest cone
roof tank in the dyke area.
Foam solution rate π x (37.5)2

= --------------- x 5
4
= 5525 lpm
Foam compound required (3%) = (5525 x 3 / 100) lpm
= 166 lpm
Foam compound quantity for 65 minutes = 166 x 65
= 10,790 litre
iii) Consider one portable foam monitor of 4500 lpm foam solution capacity:
3% Foam compound required = 135 lpm

Foam compound required for 65 minutes = 8,775 litre
iv) Consider 2 hose streams of foam with a capacity of 1140 lpm of foam solution capacity
3% Foam compound required = 68.4 lpm

Foam compound required for 65 minutes = 4,446 litre
v) Total foam compound required for cone roof tank area Protection:
Foam compound required for Cone Roof Tank = 10,790 litre
Foam Compound required for 1 Foam Monitor = 8,775 litre
Foam Compound required for 2 hose streams = 4,446 litre
Total = 24,011 litre
Say = 24,000 litres

2. FLOATING ROOF TANK PROTECTION
i) Data:
3
Total Storage Capacity in one dyke = 1,20,000 m
No. of Tanks = 2
Capacity of Each Tank = 60,000 m3
iii) Consider foam solution application rate of 12 lpm/ m2 of seal area of the single largest
floating roof tank in the dyke area :
For floating roof tank of 79 m diameter,

Diameter of the tank (D1) = 79 m
Distance of foam dam from shell = 0.8 m
Diameter of roof up to foam dam (D2) = (79- (2X0.8)) m = 77.4 m
Rim seal area = ((π /4) x (792-77.42)) m2
= 197 m2
2
Foam solution rate @ 12 lpm/ m = 2364 lpm
3% Foam Compound required = 70.9 lpm
Foam Compound required for 65 mins. = 4,609 liter
iii) Foam Compound required for 1 foam monitor and 2 hose streams as calculated for cone roof
protection
1 Foam monitor 8,775 liter
2 Hose streams 4,446 litre
iv) Total foam compound required for floating roof tank area Protection:
Foam Compound required for Floating Roof Tank 4,609 liter
Foam compound required for 1 foam monitor 8,775 liter
Foam compound required for 2 hose streams 4,446 litre
Total required 17,830 liter
Say, 18,000 liter
3. On the lines of the above example foam compound requirement should be calculated for various
dyke areas. Requirements to fight major fires in two dyke areas (with maximum foam compound
rates requirements) should be added, to arrive at the total requirement of the installation.
For example, for 2 cone roof tank dyke areas with largest tank diameter of 37.5 metres in each
area, foam compound required works out as 2x24000 liters i.e. 48,000 liters.
Similarly for 2 floating roof tank dyke areas with largest tank diameter of 79 M. in each area, foam
compound required works out as 2 X 18000 liters i.e. 36,000 liters.
4. Foam Requirement for Full surface fire of the largest floating roof tank (roof sinking Case):
considered as a single largest contingency & detailed at Annexure-VI

ANNEXURE - III
BROAD SPECIFICATIONS FOR FIRE FIGHTING EQUIPMENT
(Refer OISD STD -115 for details)
N Equip Broad Specification Capacity Suitabilit

o ment And Size y
.
I. Foam Tender - Diesel Engine Chassis with - To supply
compatible PTO Unit - 10 ton Foam
payload Solution to
- Foam compound Tank - 3000 lts. Fixed foam
- Water tank - 2600 lts. System.
- Pump capacity - 4000 lpm@
8.5 kg/sq.cm g - To supply
& 2500 lts/min form to
@ 10 kg/sq.cm g spill fires
Foam/water monitor of capacity
2500 to 2800 lts/min – 1 No.
II. Hydraulic Platform - Diesel Engine Chassis with - For foam

with articulated or compatible PTO Unit - MIN.HP280 application
telescopic arm - Foam generating equipment on oil fires
- Cage area – 1.4 sq. mt.
- Extinguishing Articulated boom - For fire fighting
Of 30 M height Of tall columns
- Throwing distance Horizontal :100-120M And inaccessible
Height: 65-75mt. area
- Boom movement – 360 degrees
- Foam/water monitor capacity
5000 to 6000 plum
- Pump capacity – 5000 to 6000
Lts/min. at 10 kg/sq. cm.g - For rescue
- Remote operation from rear of truck
- Operation to suit water
Connection from hydrants
III. DCP Tender - Diesel engine chassis –payload :13 - For gas
- 2 spheres of 2000 kg DCP each Fires and
- Expellent gas system (Nitrogen gas Spill fires
cylinders 28x50 lts at 140 kg/cm2 g
- Automatic regulator for output and range
- DCP monitor with range 15, 25 and
40 kg/second at operating pressure of
14 kg/cm2 g
- Monitor throw - 40 to 50 mtrs

IV. Emergency - Rescue equipment - For rescue

Rescue - Breathing equipment Operations
Tender - Protective clothing
- First Aid Equipment
V. Foam Tank - Foam compound storage capacity 1000 litres - For spill
Trailers with - Filed adjustable variable flow Water cum foam monitor of fires
Water-cum- capacity 1000 GPM with UL/FM listed / approved
Foam monitors
VI. Trolley mounted - Filed adjustable variable flow Water cum foam monitor of - For oil fire
Water-foam- capacity 2000 GPM with UL/FM listed / approved. Foam - For hot work
Monitors induction to the monitor shall be possible from minimum
60M distance from the monitor.
VII. Foam Nurser - Foam Compound storage - 4500 litres. - To supply

(Trailor Foam
mounted foam compound
supply tank) - Pump capacity : 160 lts/min During fire
fighting
VIII. Mobile fire - Pump capacity 1800 to 2250 - As a booster

Trailer pump Lts/min at 7 kg/sq.cm. g Pump
- Fire water use
from additional
source
IX. Fire hoses - Reinforced rubber lined hoses type - General fire
-2 ½” “A” or “B” as per IS 636 Fighting
X. Fire jeep - Standard design with two-way radio - Towing trailer

Communication facility Type
equipment
- General
vigilance
XI. Ambulance - Medical first aid equipment - Medical aid

XII. Other accessories - As per standard specifications - For fire
Foam making Lts/min at 7 kg/sq.cm. g Fighting
branch pipes,
nozzle etc.
NOTE: The capacities of equipment given above are minimum required. However, higher
capacities can be provided on need basis.

ANNEXURE - IV
FIRE TRAINING GROUND - FACILITIES
1.0 LAYOUT OF TYPICAL FIRE TRAINING GROUND
A typical layout of a fire training ground is shown in fig.1

Fig. 1
LAYOUT OF TYPICAL FIRE TRAINING GROUND
2.0 DETAILS OF FACILITIES IN TRAINING GROUND
Details of different facilities in the fire training ground are described below.
2.1. Facility for storage tank fire
Storage tanks are provided with fixed foam line connection and fixed cooling water
system to fight tank fires. The foam is to extinguish the fire and cooling water is to

prevent spreading of fire in the neighbouring tanks. Training ground should have a
tank with fixed foam installation with isolation valves on product lines.
2.2 Facility for pit fire:
During operation of the refinery, sometimes hydrocarbon liquids get released from the
process equipment and accumulate in the open areas/ pit. To fight such fires, the
facility should be provided on the ground.
2.3 Facility for pipeline fires:
In the refinery equipment are connected by pipelines and to rundown the products
from the process units to storage tanks. These pipes can leak at flange joints and
result in a fire. Facilities should be provided to simulate such fires.
2.4. Facilities for wagon gantry fire:
Gantry fires are difficult to control due to rapid spreading of fires all around the gantry.
Such fires can be controlled with the following arrangements
a) Isolate the oil supply
b) Cooling the area as well as surroundings with water spray & facilities should be
provided for such simulations.
2.5 Facilities for LPG fire
LPG is produced in the refinery and stored in containers from where it is despatched
to the market. Chances of fires due to leakage of LPG in the process unit are less as
it is processed in closed system. Probability of LPG fires during bottling;
loading/unloading of cylinders is more.
The most dangerous aspect in LPG fires is explosion of bullet/cylinders. To tackle

such fires, training facility should be installed.
2.6 Facility for high elevation column fire

In the refinery, there are tall structures such as columns/vessels. To tackle fires on
such equipment the most important activities are isolation and cooling the equipment
as well as surrounding area. Generally, isolation of inlet side of the equipment is not
much difficult, most difficult isolation is on the outlet side. To approach to the isolation
valve, personal protective equipment with water screen is necessary. Facilities should
be provided to simulate all such actions.

ANNEXURE-V
ARRANGEMENT OF MUTUAL AID
A typical arrangement through mutual aid agreement is given below:
Chembur Trombay Industrial belt spread over about 10 sq.KM is situated in north-east Greater Bombay.
Industries operating in the zone include oil refineries, chemical and petrochemical complexes, fertilizer,
power generation and a nuclear complex. The area at present is inhabited by large population living in
residential buildings, chawls and hutments. The Eastern Express Highway and Bombay-Pune Road pass
on one side of the area, while on other side; it is bounded by sea and creek. The roads in the area are
loaded with passenger and goods traffic including hazardous chemicals. A railway line for goods traffic
also runs from Kurla to the end of Corridor road, to meet the rolling stock requirement of the industries.
The industries in the area have fire fighting and emergency handling equipment and services depending
upon the nature and size of their operations. Industries have also drawn up their On-Site Emergency
Plans which are periodically revised and updated. However, the resources available with a single factory
being limited can not be sufficient to control a major emergency. To overcome such constraints, the
factories have come forward to form the Mutual Aid Scheme of Chembur-Trombay Region.
The main objective of Mutual Aid Scheme is to provide necessary help in case of emergencies when
requisitioned by any of the members, in the minimum possible time to save life, property and minimise
damage.
The members of Mutual Aid Response Group are
 Aegis Chemicals  Apar Industries  BARC  BPCL
 Bombay Paint  CTTL  HPCL  HP BDU
 IOBL  IOCL  MBPT
 ONGC  RCF  TATA Power
The members have agreed to extend help by

a) Rushing fire fighting appliances and d) Mobile equipment
equipment e) Tools, tackles and service equipment
b) Deployment of trained / technical f) Personal Protective / Special equipment
personnel g) Medical and Health Services
c) Passenger transport and ambulance
Mutual Aid members meet and discuss items of common interest like preparedness and compliance
status of Emergency Plans along following lines in scheduled meetings.
a) Location of factory, accessibility, escape c) Likely on-site / off-site emergencies
routes d) Method of communication
b) Information about hazardous chemicals e) Strengths and weaknesses.
All members carryout on-site mock drills in their respective factories as well as combined mock drill for on
site emergencies. All the real emergencies in this area have been so far effectively tackled by Mutual Aid

Guidelines for Seeking
Assistance from Mutual Aid Response Group (MARG)
1. An effort has to be made to dovetail On-site emergency plan to Off-site plan.

2. Training sessions and mock drills in First Aid, Fire Fighting, Evacuation, First Responders, should be
conducted to appraise and train different levels of responders in emergency control.
3. During an emergency assistance should be sought from the immediate neighboring MARG members
enlisted having appropriate expertise as per the guidelines and equipments, gadgets for controlling
situation and statutory authorities simultaneously.
4. All the personnel in the factory who are responders for emergencies must be made aware of the
availability of such MARG assistance and methods of getting it.
5. Assisting organization must be properly briefed by the unit seeking the assistance about the nature of
emergency, materials involved and metrological conditions ( wind direction), precise nature of help
required to ensure proper response.
6. Assisting can be requested in the form of either equipment or expertise or both with expert operating
personnel.
7. In case of equipment received from assisting organization :
a. It must be properly used.
b. Returned promptly.
c. In case of damage it should be repaired from approved agency and returned in good working
condition.
d. Consumables should be replaced / reimbursed.
8. It is understood that in case of any accident to any personnel while assisting organization that is
receiving the help should extend its co-operation in bearing a reasonable part of expenses, beyond
that covered by an insurance policy.
General:
MARG also has its limitations

Each organization is primarily responsible for keeping its plants in safe condition, identifying, assessing,
minimizing and eliminating hazards and risk, maintaining necessary equipment for special kinds of risks
that the organization might be facing and training its personnel for emergency control.
It can seek help from others in the MARG in terms of equipment, expertise and special materials.
However, it is only complimentary to its own arrangements and commitment to safety and emergency
control.
Mutual Aid and Response is sought only when in-house efforts seem to be inadequate to meet the
demand of the situation and that of the civic group is not adequately resourced to meet the sudden
requirement without loss of time.

ANNEXURE-VI
Example of Fire Case in a large Floating Roof Tank after sinking of floating roof
Example for calculation of Foam Requirement for Floating Roof tank with Portable Monitors:
DATA:
1. Diameter of Tank = 79 m
2. Type of Roof = Floating Roof
3. Foam Application Rate = 8.1 lpm
Foam Solution Requirement = π x 79 x 79

---------------- x 8.1
4
= 39,720 lpm
= 2,383 m3/hr
Say, = 2,400 m3/hr
This much quantities has to be thrown over to sunken roof area with the help of external long
range high volume monitors from the road side periphery of the tank farm. The same can be
achieved by 5 nos. of 2000 gpm such monitors. In design firewater rate calculation in Ann-I,
sinking of floating roof of the largest tank has been considered as a single largest contingency to
sizing the fire water network around tank farms to take up such firewater load so that long range
monitors can be fed from this network by diverting water available in other areas of the installation
to tank farms in such emergency.
Foam Compound Requirement = 39720 x 3 /100
= 1192 lpm
Foam Compound Requirement = (1192 x 65) litre

for 65 minutes with 3% concentration
= 77,480 litres

Annexure-VII
SYSTEM OF AUTOMATIC ACTUATED RIM SEAL FIRE DETECTION AND EXTINGUISHING
SYSTEM FOR EXTERNAL FLOATING ROOF TANKS STORING CLASS-A PETROLEUM
The automatic actuated flooding system is designed to automatically detect and extinguish the
floating roof tank rim seal fire at its incipient stage. The system is mounted on the roof of the
tank. The minimum requirement for the design of the system is given below:
1.0 Foam Flooding system:

Film Forming Fluroprotein Foam (FFFP) / Aqueous Film Forming Foam (AFFF) type
concentrate is used in the system.
1.1 Foam Application system :

A large storage tank requires one or more than one modular units for foam application in the
entire rim seal. Each such unit consists of a foam distribution pipe, laid along the tank
perimeter over the rim seal area. The spray nozzles for foam application are mounted on
the distribution pipe at suitable intervals. Distribution pipe is permanently connected to a
storage vessel containing pre-mix foam and both are placed on the roof. The foam is kept
pressurised with nitrogen. The premix foam solution is contained in a vessel which is kept
charged with nitrogen. The system is designed for minimum foam application rate of @ 18
lpm/ m2 of rim seal area. For effective control, foam is discharged in approximately 40
seconds.
1.2 Alarm & Auto-actuation system:
In case of fire on the rim seal, it is automatically detected by a device capable to sense the
same. The device then actuates the spray system for application of foam in the complete
area of rim seal to quickly extinguish the fire in its incipient stage. An audio-visual alarm is
also coupled with the detection & extinguishing system for necessary fire alert.
The system includes a fire detector network which senses fire and actuates the automatic
release of the extinguishing medium on the rim seal area. Each tank shall have independent
detection & extinguishing system.
The validity of the approach must be demonstrated by the designer for an effective total
flooding extinguishing system which quickly detects and extinguishes fire in its incipient
stage without re-flash. Also, the design considerations should include the impact of the
weight of the modules placed on the floating roof.
The detection system needs to be highly reliable and shall work at varied site ambient
temperatures for protection of rim seal fire.
The rim seal protection system shall be of linear hollow metallic tube type detectors with
foam based extinguishing media or equivalent system*, for existing, new installation as well
as for replacement of existing system when due. These detection systems shall be listed
and/ or approved by any of the international agencies like UL, FM, VdS or LPC to ensure
that those systems are used which meet the highest standards of safety.

* Refer clause at para 2.0 (iv) for equivalency
1.3 Calculations for modular Foam application system for 79 mtr dia tank:
 Rim seal area of Tank : π X 79 X 0.3 = 74.5 m2 (Considering a flexible seal area of
typically 300 mm)
2
 Rate of Foam application @ 18 LPM/ m = 1341 LPM
 Total Foam solution required in 40 sec = 894 litre
 Total nos. of Modular unit required for the tank = 7 *
* (considering a vessel of 150 litre capacity containing 135 litre of Foam)

ANNEXURE-VIII
BRIEF DESCRIPTION OF FIRE FIGHTING FOAM
1.0 FIRE FIGHTING FOAM:
Fire fighting foam is a homogeneous mass of tiny air or gas filled bubble of low
specific gravity, which when applied in correct manner and in sufficient quantity, forms
a compact fluid and stable blanket which is capable of floating on the surface of
flammable liquids and preventing atmospheric air from reaching the liquid.
2.0 TYPES OF FOAM COMPOUND

Two Types of foams are used for fighting liquid fires:
2.1 CHEMICAL FOAM: When two or more chemicals are added the foam generates due
to chemical reaction. The most common ingredients used for chemical foam are
sodium bicarbonate and aluminimum sulphate with stabilizer. The chemical foam is
generally used in Fire extinguishers.
2.2 MECHANICAL FOAM: It is produced by mechanically mixing a gas or air to a

solution of foam compound (concentrate) in water. Various types of foam
concentrates are used for generating foam, depending on the requirement and
suitability. Each concentrate has its own advantage and limitations. The brief
description of foam concentrates is given below.
3.0 MECHANICAL FOAM COMPOUND:
Mechanical foam compound is classified in to 3 categories based on its expansion

ratio.
LOW EXPANSION FOAM: Foam expansion ratio can be up to 50 to 1, but usually

between 5:1 to 15:1 as produced by self aspirating foam branch pipes.
The low expansion foam contains more water and has better resistant to fire. It is
suitable for hydrocarbon liquid fires and is widely used in oil refinery, oil platforms,
petrochemical and other chemical industries.
MEDIUM EXPANSION FOAM: Foam expansion ratio vary from 51:1 to 500:1 as
produced by self aspirating foam branch pipes with nets. This foam has limited use in
controlling hydrocarbon liquid fire because of its limitations w.r.t. poor cooling, poor
resistant to hot surface/radiant heat etc.
3.3 HIGH EXPANSION FOAM: Foam expansion ratio vary from 501:1 to 1500:1, usually
between 750:1 to 1000:1 as typically produced by foam generators with air fans. This
foam has also very limited use in controlling hydrocarbon liquid fire because of its
limitations w.r.t. poor cooling, poor resistant to hot surface/radiant heat etc. It is used
for protection of hydrocarbon gases stored under cryogenic conditions and for
warehouse protection.

4.0 TYPES OF LOW EXPANSION FOAM:
Foam concentrates to be used shall conform to IS 4989 & UL-162
4.1 PROTEIN BASE FOAM:
The foam concentrate is prepared from hydrolyzed protein either from animals or
vegetable source. The suitable stabilizer and preservatives are also added.
The concentrate forms a thick foam blanket and is suitable for hydrocarbon liquid fires,
but not on water miscible liquids. The effectiveness of foam is not very good on deep
pools or low flash point fuels which have had lengthy pre-burn time unless applied
very gently to the surface.
The concentrate is available for induction rate of 3 to 6%. The shelf life of concentrate
is 2 years.
4.2 FLUORO PROTEIN FOAM:
This is similar to protein base foam with fluro-chemical which makes it more effective
than protein base foam.
The concentrate forms a thick foam blanket and is suitable for hydrocarbon liquid fires,
but not on water miscible liquids. The foam is very effective on deep pools of low
flash point fuels which have had lengthy pre burn time.
The concentrate is available for induction rate of 3 to 6% and the shelf life is similar to
that of protein base foam.
4.3 AQUEOUS FILM FORMING FOAM (AFFF):
The foam concentrate mainly consists of fluoro carbon surfactants, foaming agent and
stabilizer. This can be used with fresh water as well as with sea water.
It produces very fluid foam, which flows freely on liquid surface. The aqueous film
produced suppresses the liquid vapour quickly. The foam has quick fire knock down
property and is suitable for liquid hydrocarbon fires. As the foam has poor drainage
rate, the effectiveness is limited on deep pool fires of low flash point fuels which have
lengthy pre burn time.
The concentrate is available for induction rate of 3 to 6% and the shelf life is more
than 15 years. This can also be used with non aspirating type nozzles.
4.4 MULTIPURPOSE AFFF:
Multipurpose AFFF concentrate is synthetic, foaming liquid designed specially for fire
protection of water soluble solvents and water insoluble hydrocarbon liquids. This can
be used either with fresh water of sea water.
When applied it forms foam with a cohesive polymeric layer on liquid surface, which
suppresses the vapour and extinguishes the fire. The foam is also suitable for deep
pool fires because of superior drainage rate and more resistive to hot fuels/radiant

heat.
The 3% induction rate is suitable for liquid hydrocarbon fires and 5% for water
miscible solvents. The shelf life of concentrate is not less than 10 years. This can
also be used with non aspirating type nozzles.
4.5 FILM FORMING FLOURO PROTEIN (FFFP);
FFFP combines the rapid fire knock down quality of conventional film forming AFFF
with the high level of post fire security and burn back resistance of flouro protein foam.
The concentrate can either be used with fresh water or sea water.
The foam is suitable for hydrocarbon liquid fires including deep pool fires of low flash
point fuels which have had lengthy pre burn time.
The concentrate is available for induction rate of 3 to 6% and the shelf life is not less
than 5 years. This can also be used with non aspirating type nozzles.
5.0 TYPES OF MEDIUM AND HIGH EXPANSION FOAM:
Synthetic foam concentrate is used with suitable devices to produce medium and high
expansion foams. This can be used on hydrocarbon fuels with low boiling point. The
foam is very light in weight and gives poor cooling effect in comparison to low
expansion foams. The foam is susceptible to easy break down by hot fuel layers and
radiant heat.
The induction rate in water can vary from 1.5 to 3%.
Many of the low expansion foam concentrate can also be used with suitable devices
to produce medium / high expansion foam.

Annexure-IX
Explanatory Note indicating Implementation schedule
Clause 4.2.3 Automatic actuated rim seal fire detection and extinguishing
system shall be provided on all external floating roof tanks
storing Class A petroleum.
i) The rim seal protection system shall be implemented in all existing installations
progressively within 24 months for class A floating roof tanks above 5000 KL capacity &
balance class A floating roof tanks progressively in 36 months from October, 2010.
ii) Installation of rim seal system shall be done for all new/upcoming external floating roof
tanks storing Class A petroleum storage tanks along with commissioning of the tank.
iii) The automatic actuated rim seal fire detection & extinguishing system already provided in
the existing tanks shall be replaced with a linear hollow metallic tube type detectors with
foam based extinguishing media or equivalent system* whenever the existing system is
due for replacement or shall be replaced, within a period of 4 years from the from the day
of installation whichever is earlier.
* Refer clause at para 2.0 (iv) for equivalency
Clause 5.7.4 Remote operated High Volume Water cum Foam Monitors
i) Shall be provided progressively within 24 months from October, 2010 for existing tank
farms.
ii) Installation of monitors for all new/upcoming tanks shall be done along with commissioning
of the tanks.
Clause 14.1.3 DETECTION AND ALARM SYSTEM
i) Hydrocarbon Detectors shall be provided progressively within 24 months from October,

2010 for existing locations.
ii) For new/upcoming locations it shall be implemented along with commissioning of the
facilities.

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OISD STANDARD - 116

FIRE PROTECTION FACILITIES

PETROLEUM REFINERIES & OIL/GAS PROCESSING PLANTS

OISD – STD – 116

Oil Industry Safety Directorate

OISD STANDARD - 116

Second Edition, August 2007

FOR RESTRICTED CIRCULATION ONLY

FIRE PROTECTION FACILITIES

OIL INDUSTRY SAFETY DIRECTORATE

Petroleum industry in India is significantly globalized at present in terms of technology content

Oil Industry Safety Directorate

OISD (OIL INDUSTRY SAFETY DIRECTORATE)

Though every effort has been made to assure the

These documents are intended only to supplement and

Name Designation / Organisation Status

FIRE PROTECTION FACILITIES FOR PETROLEUM

SL.NO. DESCRIPTION PAGE NO.

SECTION DESCRIPTION PAGE NO.

Example for calculation of Foam Compound Requirement 40

Brief description of fire-fighting foam 52

OISD – STD – 116 Page No. 1

FIRE PROTECTION FACILITIES FOR PETROLEUM REFINERIES

OISD – STD – 116 Page No. 2

iii) LPG BOTTLING PLANT

iv) PETROLEUM DEPOTS, TERMINALS AND OIL & GAS INSTALLATIONS

These include locations where Petroleum crude/Products/LPG are received by tanker,

a) General Classification of Petroleum Products:

Class 'A' Petroleum: Liquids having flash point below 23 degrees C.

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Excluded Petroleum: Liquids having flash point of 93 degrees C and above.

4.0 FIRE PROTECTION PHILOSOPHY

4.1 GENERAL CONSIDERATIONS

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(NBC) / statutory regulations.

- Fire Water System

4.2 DESIGN CRITERIA

Fire water requirements shall be as per guidelines given in Annexure-l.

4.2.1 Fixed Water Spray on storage Tanks

- Floating roof tanks of diameter larger than 30 M.

4.2.2 Semi-fixed Foam system for Storage

i) Semi-fixed Foam system shall be provided for the following tanks:

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(Refer Explanatory Note for implementation in Annexure-IX).

* Refer clause at para 2.0 (iv) for equivalency.

4.2.5 Water Spray System in Process Unit

4.2.6 Water Spray for Electrical Installation

4.2.8 Loading / unloading Gantry

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5.0 FIRE WATER SYSTEM

5.2 FIREWATER FLOW RATE

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5.4 STORAGE & MAKE-UP WATER

5.4.1 FIREWATER STORAGE

5.4.2 MAKE UP WATER

5.5 FIREWATER PUMPS

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5.5.1 Type of Pumps