Fire Protection in Refineries

API RECOMMENDED PRACTICE 2001 NINTH EDITION, APRIL 2012

Fire Protection in Refineries

Downstream Segment

API RECOMMENDED PRACTICE 2001 NINTH EDITION, APRIL 2012

Special Notes

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Users of this Recommended Practice should not rely exclusively on the information contained in this document. Sound business, scientific, engineering, and safety judgment should be used in employing the information contained herein.

API is not undertaking to meet the duties of employers, manufacturers, or suppliers to warn and properly train and equip their employees, and others exposed, concerning health and safety risks and precautions, nor undertaking their obligations to comply with authorities having jurisdiction.

Information concerning safety and health risks and proper precautions with respect to particular materials and condi- tions should be obtained from the employer, the manufacturer or supplier of that material, or the material safety data sheet.

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Copyright © 2012 American Petroleum Institute

Foreword

API’s Fire Protection in Refineries, First Edition, appeared in 1933 as the beginning of fire safety guidance series for the “downstream” segment. This Ninth Edition recommended practice builds on experience gained over seven decades.

The term fire protection used in this publication includes measures taken to prevent fires, as well as those to minimize, control, or extinguish fires already burning. A thorough approach to fire protection starts with an understanding of the ignition and combustion processes, including control of potential fuel sources with an emphasis on containment. This publication gives some basic information on these subjects and identifies sources of more detailed information. While sections of this document discuss general design principles, it is not intended as a design manual. Rather, it presents guidance for those providing fire protection services to refineries and gives reference to sources of more detailed design related information.

The information presented is based primarily upon experience in a large number of refineries. It is not intended to exclude or limit the use of other approaches of comparable merit.

Fire protection references comprise a very large body of literature. API 2001 points to many of these references relevant to refineries while seeking not to duplicate them. Most of these references are not incorporated as “normative,” and the user is advised to determine their relevance for specific applications.

Nothing contained in any API publication is to be construed as granting any right, by implication or otherwise, for the manufacture, sale, or use of any method, apparatus, or product covered by letters patent. Neither should anything contained in the publication be construed as insuring anyone against liability for infringement of letters patent.

This document was produced under API standardization procedures that ensure appropriate notification and participation in the developmental process and is designated as an API standard. Questions concerning the interpretation of the content of this publication or comments and questions concerning the procedures under which this publication was developed should be directed in writing to the Director of Standards, American Petroleum Institute, 1220 L Street, NW, Washington, DC 20005. Requests for permission to reproduce or translate all or any part of the material published herein should also be addressed to the director.

Generally, API standards are reviewed and revised, reaffirmed, or withdrawn at least every five years. A one-time extension of up to two years may be added to this review cycle. Status of the publication can be ascertained from the API Standards Department, telephone (202) 682-8000. A catalog of API publications and materials is published annually by API, 1220 L Street, NW, Washington, DC 20005.

Suggested revisions are invited and should be submitted to the Standards Department, API, 1220 L Street, NW, Washington, DC 20005, standards@api.org.

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1. Purpose and Scope 1

   1. Purpose 1

   2. Scope 1

   3. Concept of Hazard vs Risk 1

2. Normative References 1

3. Terms and Definitions 2

4. Chemistry and Physics of Fire—Special Considerations 4

   1. Chemistry and Physics of Fire 4

   2. Special Situations, Considerations, and Hazards 4

5. Fire Considerations in Refinery Design 4

   1. General 4

   2. Hazard Analysis 4

   3. Process Design 5

   4. Equipment Design 6

   5. Location 14

   6. Layout 14

   7. Fireproofing 19

   8. Pressure Relief and Flare Systems 20

   9. Drainage, Containment, and Waste Disposal 22

   10. Power and Utilities 23

6. Fire Control and Extinguishing Equipment 25

   1. General 25

   2. Water for Fire Suppression 26

   3. Foam 33

   4. Dry Chemicals 34

   5. Combined (Dual) Agents 35

   6. Clean Agent Fire Extinguishing 35

7. Operating Practices 37

   1. General 37

   2. Normal Operations 37

   3. Emergency Operations 39

   4. Loss of Containment 40

8. Maintenance Procedures 41

   1. General 41

   2. Hot Work 41

   3. Planned Maintenance Activities 42

   4. Winterizing and Freeze Protection 42

9. Emergency Response Organization 43

   1. General 43

   2. Incident Command System (ICS) 43

   3. Duties of Fire Protection Staff 44

   4. Notification Procedures 44

   5. Firefighter Selection and Training 45

   6. Incident Commander 46

   7. Firefighter Personal Protective Clothing and Equipment 46

      
      

10. Training for Firefighting 46

    1. General 46

    2. Drill Ground Training 47

    3. Classroom Instruction 48

    4. Overcoming Personal Concerns 48

    5. Documentation 49

11. Prefire Incident Planning 49

    1. General 49

    2. Prefire Incident Planning 49

Annex A (informative) Chemistry and Physics of Fire 51

Annex B (informative) Cold Weather Hazards, Winterizing, and Freeze Protection 57

Annex C (informative) Conversion Factors 65

Bibliography 67

Figures

1 Figure 5 from API 2021, Fourth Edition, “Water-Foam Solution Flow Requirement for

Full Surface Fire, gallons per minute at Varied gpm/ft2 Application Rates” 30

A.1 Fire Tetrahedron Diagram 51

Tables

1. Example Water Flow Rates for Manual Firefightinga 28

2. Suggested Residual Pressures 29

1. Historical Freezing Weather Incident Examples 59

2. Winterization Audit Checklist 61

3. Winterization “Discovery” Dead-Leg Surveillance—Samples of Things to Look for

   When Evaluating Dead-Legs 62

4. Sample—Winterization Checklist—Example of One Approach 63

C.1 U.S. Customary (USC) to Metric (SI) Units of Measure 65

Fire Protection in Refineries

1. Purpose and Scope

   
   

   1. Purpose

      
      

      The purpose of this recommended practice is to provide a better understanding of refinery fire protection and the steps needed to promote the safe storage, handling, and processing of petroleum and petroleum products in refineries. A basic premise of this standard is that fire prevention provides the fundamental foundation for fire protection.

      
      

   2. Scope

      
      

      This document covers basic concepts of refinery fire prevention and protection. It reviews the chemistry and physics of refinery fires; discusses how the design of refinery systems and infrastructure impact the probability and consequences of potential fires; describes fire control and extinguishing systems typically used in refineries; examines fire protection concepts that should be covered in operating and maintenance practices and procedures; and provides information on organization of and training for refinery emergency responders. Many of the concepts, systems, and equipment discussed in this document are covered in detail in referenced publications, standards, or governmental requirements.

      
      

   3. Concept of Hazard vs Risk

      
      

      Hazards are situations or properties of materials with the inherent ability to cause harm. Flammability, toxicity, corrosivity, and stored electrical, chemical, or mechanical energy all are hazards associated with various industrial materials or situations.

      
      

      Risk requires exposure. A hot surface or material can cause thermal skin burns or a corrosive acid can cause chemical skin burns, but these can occur only if there is contact exposure to skin.

      
      

      A person working at an elevated height has “stored energy” and a fall from a height can cause injury—but there is no risk unless a person is indeed working at heights and thus exposed to the hazard. There is no risk when there is no potential for exposure.

      
      

      Determining the level of risk for any activity involves understanding and recognizing hazards, then estimating the probability and severity of exposure events that could lead to harm or damage, and the resulting consequences. Principles relating hazards to the risk for people are valid for evaluating property or environmental risk. For instance, hydrocarbon vapors in a flammable mixture with air can ignite if exposed to a source of ignition resulting in a fire that could cause property damage as well as injure people. Hydrocarbons that will burn are hazardous materials—but one element of risk includes a flammable fuel-air mixture being exposed to an ignition source.

      
      

2. Normative References

The following referenced documents are indispensable for the application of this document and are normative in those geographic areas under U.S. federal OSHA jurisdiction. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies. The bibliography organizes other references and sources of additional information by primary subject area. Additional information may be available from the Internet sites cited therein.

NFPA 30 1, Flammable and Combustible Liquids Code

1 National Fire Protection Association, 1 Batterymarch Park, Quincy, Massachusetts 02169, www.nfpa.org.

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