Maintenance
Maintenance
MAINTENANCE
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Important Definitions
LOSS – Avoidable waste of any resource.
OXYGEN HEAT
FUEL
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FIRE TETRAHEDRON
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The Fire Tetrahedron (A pyramid)
For many years the concept of fire was symbolized by the Triangle of
Combustion and represented, fuel, heat, and oxygen. Further fire
research determined that a fourth element, a chemical chain reaction,
was a necessary component of fire. The fire triangle was changed to a
fire tetrahedron to reflect this fourth element. A tetrahedron can be
described as a pyramid which is a solid having four plane faces.
Essentially all four elements must be present for fire to occur, fuel,
heat, oxygen, and a chemical chain reaction. Removal of any one of
these essential elements will result in the fire being extinguished.
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Fire chemistry
The combustion process is usually associated with
the oxidation of a fuel in the presence of oxygen
with the emission of heat and light.
Oxidation, in the strict chemical sense, means the
loss of electrons. For an oxidation reaction to
occur, a reducing agent the fuel, and an oxidizing
agent, usually oxygen must be present. As heat is
added, the ignition source, the fuel molecules and
oxygen molecules gain energy and become active.
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Fire chemistry
This molecular energy is transferred to other fuel
and oxygen molecules which creates a chain
reaction. A reaction takes place where the fuel
looses electrons and the oxygen gains electrons.
This exothermic electron transfer emits heat and/or
light. If the fire is in a fire grate/ or furnace we refer
to this process as a controlled fire, and it is a
building on fire we refer to this process as a
uncontrolled fire.
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METHODS OF EXTINGUISHMENTS OF FIRE
1. STARVATION : ELIMINATION OF FUEL
2. SMOTHERING : LIMITING OF OXYGEN
3. COOLING : LIMITING TEMPERATURE
4. INHIBITION OF CHAIN REACTION
STARVATION : Removal / cut off the fuel supply.
SMOTHERING : Cut off the air / Oxygen
COOLING : Removal of heat / Temperature.
INHIBITION OF CHAIN REACTION: Removal of hydrogen and
hydroxyl radicals generated due to heat and oxidation
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CLASSIFICATION OF FIRE
Class of Description Extinguishing Media
Fire
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PROPERTIES OF PETROLEUM
EXPLOSIVE LIMITS: These are the extreme
concentrations of a flammable vapour in air above and
below which propagation of flame will not occur.
LOWER EXPLOSIVE LIMIT : The minimum
concentration of a particular combustible gas or vapor
necessary to support its combustion in air is defined as the
Lower Explosive Limit (LEL) for that gas. Below this level,
the mixture is too “lean” to burn.
UPPER EXPLOSIVE LIMIT :The maximum concentration
of a gas or vapor that will burn in air is defined as the Upper
Explosive Limit (UEL). Above this level, the mixture is too
“rich” to burn. The range between the LEL and UEL is known
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the flammable range for that gas or vapor. 12
METHODS OF EXTINGUISHMENT
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STARVATION
The extinction of fire by starvation can be done in
following three ways
a)By removing combustible material from the neighbour hood
of fire.
b)By removing material on fire from the vicinity of combustible
Materials.
c)By subdividing the burning material into small sized fires.
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SMOTHERING
If the oxygen content of the atmosphere in the
immediate neighbourhood of the burning material
can be reduced, combustion will cease.
The method involved is to prevent or impede the
access of fresh air to seat of fire and allow the
combustion to reduce oxygen content.
Diluting the air by inert gas like co2,dcp,steam,
Blanketing the fuel supply by gas tight barrier
like foam
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COOLING
The rate at which heat is dissipated is more than the
rate at which heat is generated the combustion
cannot persist.
In applying the principle to fire extinction the first step is to
accelerate the speed with which the heat is removed from
the fire, thus reducing the temperature of the burning mass
and as a consequence the rate at which heat is produced. In
due course the rate at which heat is lost from fire exceeds the
rate of heat generation and the fire dies away
METHODS:
Direct- water jet, water vapourises, production of
steam
Indirect-water fog, CO2, DCP
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INHIBITION OF CHAIN REACTION
• The hydrogen and hydroxyl radicals i.e. the
chain carriers are to be prevented to react in
the flame front .
• It is the effective method in extinguishment of
burning hydrocarbons. This is the principle of
vapourising liquids
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ACCESSORIES
EXPLOSIMETER
SPARK ARRESTOR
RESUSCITATION SET
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BURNING CHARACTERISTICS OF HYDROCARBONS
BOIL OVER
The heat wave which develops in
crude oil or heavy oils, when it
comes in contact with water under
the oil surface causes the upper
layer of water to convert
immediately into steam causing
tremendous increase in volume. the
steam oil forth comes out as a wave
of burning oil out of the tanks &
then falls spreading even beyond the
dyke walls of the tank. this is called
the boil over.
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BLEVE (BOILING LIQUID EXPANDING VAPOR EXPLOSION)
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BLEVE (BOILING LIQUID EXPANDING VAPOR EXPLOSION)
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FIRE MANAGEMENT AT
PIPELINE INSTALLATION
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TYPES OF FIRE PROTECTION
PASSIVE FIRE PROTECTION: is an integral
component of the three components of structural fire
protection and fire safety in a building. PFP attempts to
contain fires or slow the spread, through use of fire-
resistant walls, floors, and doors (amongst other
examples). PFP systems must comply with the
associated Listing and approval use and compliance in
order to provide the effectiveness expected by building
codes. It can be as:
Fire proofing
Dyke walls
Proper layout
Segregation of hazard
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PASSIVE FIRE PROTECTION
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ACTIVE FIRE PROTECTION
ACTIVE FIRE Protection: is an integral part
of fire protection. AFP is characterized by items
and/or systems, which require a certain amount of
motion and response in order to work, contrary
to passive fire protection.
Fire suppression
Sprinkler systems
Fire detection
Hypoxic air fire prevention
first aid fire fighting equipments.
mobile fire fighting equipments.
fixed fire fighting systems
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FIRST AID FIRE FIGHTING EQUIPMENTS
1. Fire Extinguishers
DCP fire extinguishers
CO2 fire extinguishers
Halon extinguishers
Water base extinguishers
Foam extinguishers (Protein Foam, Fluoroprotein Foam, Aqueous Film
Forming Foam (AFFF), Film Forming Fluoroprotein Foam (FFFP), Alcohol
Type AFFF, Alcohol Type FFFP, Expansion foam (Mid Expansion Foam and
High Expansion Foam. A
2. Hose Reels
3. Fire Blankets
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MOBILE FIRE FIGHTING EQUIPMENTS
1. Fire Fighting Tenders
Foam tenders : 4 nos.
DCP tender : 1 no.
Foam Nurser : 2 nos.
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FIXED FIRE FIGHTING SYSTEMS
1. Fire water net work
2. Fire water booster pumps
3. Fire water storage
4. Fire hydrants.
5. Fire monitors
6. Foam pourers in storage tanks
7. High volume long range monitors
8. Elevated remote operated monitors
9. Automatic fire detection and extinguishing systems in tanks.
10. Local fire water booster pumps in new units.
11. Smoke detectors in buldings & sub stations.
12. Gas detectors in units.
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FIXED FIRE FIGHTING SYSTEMS
13. Fire water sprinklers
14. CO2 flooding systems in gts
15. Clean agent base detection and
extinguishing system in new
control rooms.
16. Field alarm points –
17. Fire sirens
18. Fire call phone system
101 / 4333
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GOALS OF LOSS CONTROL MANAGEMENT
1. IDENTITY ALL LOSS EXPOSURES.
Planned inspections.
Group meetings
Accident investigations & reports.
2. EVALUATE THE RISK
Hi-Risk identification
Risk severity
Frequency of exposure
Probability of loss.
3. DEVELOP A PLAN
Terminate
Treat
Transfer
Tolerate
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GOALS OF LOSS CONTROL MANAGEMENT
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EXTINGUISHING MEDIA
Water
Foam
Carbon
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dioxide 32
FOAM
It is considered to be the best extinguishing medium
for Class B fires.
The foam is the mass of air bubbles formed by
aeration of foam solution made up of the water and
foam concentrate.
The foam extinguishes the fire of liquid hydrocarbons
Insulating the surface of fuel. Prevent release of
vapours. Prevent mixing of vapour and atmospheric
oxygen forming a blanket
The foam is classified in two types depending on the
method of generation
i.e. chemical and mechanical foam
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Aqueous film forming foam
Aqueous film forming foam - It is the most
commonly used synthetic foam in petroleum industries. It
has unique property of forming a film on the surface of
the liquid. It has low viscosity and surface tension. Hence
it floats on the surface of the liquid and spreads to cover
all the area. Even if the film is broken it has a
characteristic to bleed back which means it reseals the
surface due to which flashback is avoided. It has longer
shelf life of 15 years and excellent flashback resistance.
Effective knocking down property on spill fires.
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FOAM SYSTEM
Semi fixed foam pourer system :
Fixed piping network and mobile foam supply.
Mobile system :
Foam tender, Foam trolley, Foam tower.
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FOAM POURER SYSTEM
Wind shield
4” Foam pourer
Dam width
Foam maker
Floating roof
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Foam seal 36
PORTABLE FIRE EXTINGUISHERS
Every fire is small when it starts. At incipient
stage fire is small and heat and smoke released
is also considerably less. Hence it is easy to
extinguish fire at incipient stage
Fire extinguishers have limited quantity of
extinguishing media, limited range and limited
duration, hence meant for tackling the fire at its
inception. Thus they are called as first aid fire
fighting equipment.
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DRY CHEMICAL POWDER EXTINGUISHER
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DRY CHEMICAL POWDER
The dry chemical powder is used to extinguish
the Class B and Class C fires. The DCP for
Class A fires is also available and for Class
D fires special dry chemical is used.
The most commonly used DCP are
1. Sodium Bicarbonate.
2. Potassium Bicarbonate.
3. Monoammonium Phosphate. It also called
as ABC powder as it can be used on Class
A, B, C fires.
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75/50 Kg DCP Extinguisher
This extinguisher is similar to that of 10 Kg.
Capacity except it is bigger in size and is wheel
mounted.
The expellant CO2 gas is stored in a separate
cylinder fitted with the extinguisher body. This
arrangement makes slight a changes in
operation and the construction of cap
assembly.
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CARBON DIOXIDE TYPE FIRE EXTINGUISHER
This type of extinguisher is
suitable for Class B, Class
C fires. The fire is put off
by following action.
Smothering of fire by
displacement of oxygen
Cooling effect due to rapid
physical change. Liquid
CO2 when converted to
gas has an expansion ratio
of 1:450 and it is this high
expansion ratio brings the
cooling effect.
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CARBON DIOXIDE TYPE FIRE EXTINGUISHER
Since CO2 is non conductor of electricity it can be used in
electrical fires. The clean extinguishing property makes it
suitable for use on sophisticated electrical and electronic
equipments.
Construction: It consists of pressure container made of steel, a
valve for releasing CO2 , with locking safety pin and
discharge tube with horn for an effective application of CO2 on
fire. The container is charged with CO2 in liquid form, stored
at pressure of 51 Kg/ cm2.
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Schematic layout of Conventional
detection system
Zone-1 S P S
Control Panel
Zone-2 T S P
Zone-3 S T P
S - Smoke
T - Heat
H P - Manual call point
H- Hooter
H
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Schematic layout of Analog
addressable detection system
Loop S P S
Central Panel
C S P
C T P
C - Controller
S - Smoke
Computer H T - Heat
P - Manual call point
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H- Hooter 46
USE OF PPEs
Hand and Arm Protection-- It becomes necessary to
protect hand and arm when workers have to handle materials
having sharp edges, hot and molten metals corrosive
substances etc. PPE available are :
Hand gloves, gauntlets, wrist, sleeves, hand pad etc.
Rubber hand gloves are used when acid, alkali, and other
corrosive substances, oil or grease are handled. Leather
gloves are used during welding operations and while
handling metal sheets and sharp objects.
Foot and leg protection -- To protect foot from falling of
heavy materials , splash of molten metals, Striking against
hard object.
Safety shoe, Gumboot are common protective Equipments.
Safety shoe with steel toe cap prevent from falling objects.
Gumboots prevent from electric shock, hot liquids, moisture,
acids alkalies etc.
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FIRE PROXIMITY SUIT
These suits are used during fire fighting
operations . Proximity suit is used to approach
the fire from the nearest possible distance. It has
capability to reflect 95% of the heat by the reflecting
surface. It can be used in the vicinity of temperature
of around 1000oC. It should not be used to enter in
the fire.
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Safety Belt
As per The Factories Act 1948, any person
working at height of more than 2 metres is required
to wear the safety belt.
It consists of leather belt of 3 inches in width tied
with ‘D’ ring at the back of fastening a rope.
While working, safety belt should be worn with
rope, one end fastened to ‘D’ ring and other to a
fixed structure.
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WATER GEL BLANKET
It is a life saving cum fire fighting device. It contains Gel which
is basically de-ionized water as a base (97%) and rest 3% is
Glycerine, Keglum etc. The blanket in which the Gel is soaked
is a woolen blanket having intracellular weave which enables
easy absorption of gel. The blanket is capable of absorbing gel
13 times of its own weight.
Use :
First Aid – Place the victim on the ground, wrap the blanket
around him. Mold the body and leave the victim wrapped in the
blanket till the medical is sought. It is very effective in the
primary emergency treatment of burns. It brings relief to
damaged tissues, reduces pain and prevents possible external
contamination/infection of burn areas.
For fire fighting place the blanket over the source of the flame.
Shelf life of the WGB is 3 yrs for first aid medical use and 5 yrs
for fire fighting. Do not use the blanket on burn victims if the
bag inside is found open.
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WATER JEL BLANKET AND RESUSCITATION SET
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Noise Protection & BA sets
Noise protection : The protective Equipments used are earmuffs
and earplugs.
Ear muffs consists of a plastic cup with a cushion material
made up of foam rubber. It covers external to give protection
from high noise level such as 130 db to 135 db.
Ear plugs are inserted in ear and give protection from noise
levels of 115 db to 120 db.
BA sets:
Fire fighters, Rescuers often require to work in oxygen
deficient, toxic atmospheres. To survive in such atmospheres
they must be given an equipment ensuring adequate protection
and supply of air throughout the operation. Hence the Breathing
Apparatus sets are used.
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DAMAGE TO THE HOSE
Abrasion : Abrasion of the hose is caused by :
Dragging of charged/ dry hose.
Allowing the vehicles to pass over when laid out.
To prevent the abrasion the hose should never be
dragged and no vehicle allowed to pass over it.
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For pipeline installations
For pipeline installations, the portable extinguisher shall
be provided as per the list, suitably amended along with
following additions:-
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For pipeline installations
Sump Pump / Trans mix Pump & Oil Water Separator Pump :
1 No. 10 Kg DCP extinguisher.
Scrapper Barrel : 1 No. 10 Kg DCP extinguisher.
Control Room : 2 Nos. 2.5 Kg Clean Agent and 1 No. 4.5 Kg CO2
extinguisher.
UHF / Radio Room : 2 N o s. 2.5 Kg Clean Agent and 1 No. 4.5
Kg CO2 extinguisher.
Meter Prover/Separator Filter : 1 No. 10 Kg DCP extinguisher.
Repeater Station :1 No. 10 Kg DCP & 1 No. 2 Kg CO2
extinguisher.
Mainline Emergency Equipment Centre : 4 Nos. 10 Kg DCP & 2
Nos. 2 Kg CO2 extinguishers.
Air Compressor : 1 No. 2 Kg CO2 & 1 No. 5 Kg DCP
extinguisher.
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For pipeline installations
Accessories
The following minimum no. of Personal Protective Equipment, First
Aid Equipment & Safety
Instrument shall be provided as indicated against each item.
Sand drum with scoop: 4 Nos.
Safety helmet: 1 No. per person.
Stretcher with blanket: 2 Nos.
First Aid box: 1 No.
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For pipeline installations
ITEMS QUANTITY
• Sand Scoops 4 Nos.
• Safety helmets 8 Nos.
• Water curtain nozzles 2 Nos.
• Stretcher 1 No.
• First Aid Box with Anti snake serum 1 No.
• Rubber hand gloves for electrical jobs 3 Nos.
• Explosimeter 1 No.
• Fire Proximity suit 1 No.
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• ITEMS QUANTITY
• Rescuscitator 2 Nos.
• Electrical siren (3 Km range) 1 No.
• Hand operated siren 1 No.
• Water jel blanket 1 No.
• Red/Green flag for fire drill 1 No.
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FIRE PROTECTION FACILITIES REQUIRED FOR
PETROLEUM DEPOTS, TERMINALS & PIPELINES
INSTALLATIONS AS PER OISD-117
Provisions:
Fire water system
Foam system
Halon system
First aid fire fighting equipment
Mobile fire fighting equipment
Fire alarm/ communication system
Fire water pond(s)/above ground tanks for storage of water for f/f
Engine&/motor driven f/f pumps, jocky pumps-for keeping the line
pressurised
Fire water network with fire hydrants & monitors
Portable fire extinguisher
Automatic fire detection and alarm system
F/F/ accessories like hoses, branches, nozzles, portable monitors, foam
branches etc
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FIRE PROTECTION FACILITIES IN
PIPELINE INSTALLATION
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Foam making Branch
In tackling oil fire with foam, a rapid rate of delivery of foam is of
great advantage. FB 5x is used to fight the oil fires.
Dividing breaching : It divides one length of hose delivering
water into two .
Collecting Breaching : It is used for the collecting water from two
hoses and delivers into one when the demand of water is more.
Water curtain : It is a plate welded to the male coupling. When the
hose is connected it gives a curtain of water, used mainly for the
protection of fire fighters from heat radiation.
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•
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Universal type branch
This branch can give a jet and spray the delivery of the water can be
shut off. The jet is used for tackling ordinary class A fires. The spray is
used for the purpose as:
a. Dispersing the vapours.
b. Cooling the equipments/ area to prevent to spread of fire.
c. Providing the water curtain to fire fighters against heat radiation.
d. Extinguishing Class A fires and fires involving high flash points
products.
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SPRINKLER SYSTEM
Sprinkler nozzle
12 “ FW line
8” line
6” line
Non return valve.
8” Gate valve.
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Sprinkler nozzles
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SPRINKLER NOZZLE (Brass/ SS)
Deflector
Deflector pin
Housing
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CODES AND STANDARDS
OISD- 117, 118, 105, 142
NFPA guidelines
TAC guidelines
FACTORY ACT
CCE GUIDELINES
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No work is so urgent
&
No work is so important that
to perform it safely.
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