Spec. Safety and Fire Protection - SJB

JOB NO.

9 3 2 8

DOC. NO.

PS-1100-MEC-019

REV.

R1

DATE : 05 FEBRUARY 2003 SHEET : 1 OF 166

PREP’D LUKMAN LUK

SOUTH JAMBI “B” SHALLOW GAS PROJECTCHK’D RUSHLIE E REFAPP’D INDRA N IDR

Specification For

SAFETY AND FIRE PROTECTION

REV DATE PAGES DESCRIPTION PREP’D CHK’D APP’D COMPANY

R1 30/10/02 ALL Issued for Approval MUCH GNS IDR DJV

0 05/02/03 ALL Issued for Construction

GULF RESOURCES (SOUTH JAMBI) Ltd.

T R I P A T R A TOYO-

South Jambi “B” Shallow Gas Project

TABLE OF CONTENT

1. GENERAL...............................................................................................................................................0

1.1 SCOPE...............................................................................................................................................01.2 GENERAL..........................................................................................................................................01.3 DEFINITIONS OF TERMS.....................................................................................................................01.4 VENDOR RESPONSIBILITY..................................................................................................................01.5 REFERENCED PUBLICATIONS..............................................................................................................01.6 CONFLICTING REQUIREMENTS...........................................................................................................0

2. GENERAL SAFETY AND FIRE PROTECTION PHILOSOPHY......................................................0

3. FACILITY LAYOUT..............................................................................................................................0

3.1 BASIC PRINCIPLES.............................................................................................................................03.2 DETAIL REQUIREMENTS.....................................................................................................................0

4. FIRE PROTECTION SYSTEMS...........................................................................................................0

4.1 GENERAL..........................................................................................................................................04.2 FIRE WATER SYSTEM........................................................................................................................04.3 PASSIVE FIRE PROTECTION................................................................................................................0

5. PERSONNEL SAFETY AND PLANT SECURITY..............................................................................0

5.1 PERSONNEL SAFETY EQUIPMENT.......................................................................................................05.2 Noise Control....................................................................................................................................0

APPENDIX 1 ……………………………………………………………………………………………..16

TRIPATRA – TOYO CONSORTIUM PS-1100-MEC-019 R1File: document.doc of 16


1. GENERAL

1.1 Scope

The purpose of this document is to specify the basic safety and fire protection systems and arrangements to be provided for and installed on Gulf Indonesia Resources facilities.

1.2 General

This specification covers safety, fire protection, personnel safety and security aspects of the permanent Gas Plant facilities.

1.3 Definitions Of Terms

Vendor - The supplier of equipment, materials or services

Purchaser - The organization responsible for procurement of equipment, material or

services. The Purchaser may be a contractor or agent of the Company itself.

Company - The subsidiary of Gulf Indonesia Resources noted in the EPC Contract as

applicable.

Contractor - shall mean the organization appointed by the Company to carry out the

detailed engineering, procurement and construction (EPC) phases of the

project.

Definitions of terms are as follows :

API American Petroleum Institute

CGP Central Gas Plant

FM Factory Mutual

HVAC Heating, Ventilation And Air Conditioning

IP Institute of Petroleum

ISO International Standards Organization

QA Quality Assurance

NFPA National Fire Protection Association

AFFF Aqueous Film Forming Foam

UL Underwriters Laboratories

1.4 Vendor Responsibility

The Vendor shall be responsible for the complete design, fabrication, supply, inspection and testing of the safety and fire protection systems, in full compliance with the requirements of this Specification, Indonesian Government Legislation and Regulations, MIGAS and all applicable design Codes and Standards.



1.5 Referenced Publications

1.5.1 Gulf Indonesia standards

PS-1156-ICC-001 Specification for Process Control System

PS-1100-ICC-002 Specification for Fire And Gas Detection System

PS-1100-ICC-001 Specification for Instrument General Requirement

1.5.2 American Petroleum Institute

API Publication 2021 – Guide to Fighting Fire around

Petroleum Storage Tanks.

API RP 2001 – Fire Protection in Refineries.

API Publication 2030 – Guidelines for Application of Water Spray

System for Fire Protection in the Petroleum

Industry.

API Publication 2218 – Fireproofing Practices in Petroleum and

Petrochemical Processing Plants.

API Recommended Practice – 750 ‘Management of Process Hazards’.

American Institute of Chemical Engineers – Guidelines for Process Safety Management Systems.

1.5.3 National Fire Protection Association

NFPA 10 - Standard for Portable Fire Extinguisher

NFPA 11 - Low Expansion Foam and Combined Agent

Systems

NFPA 12 - Carbon Dioxide Systems

NFPA 13 - Sprinkle Systems

NFPA 14 - Installation of Standpipe and Hose Systems

NFPA 15 - Water Spray Fixed Systems for Fire Protection

NFPA 20 - Installation of Stationery Pumps for Fire Protection

NFPA 22 - Water Tanks for Private Fire Protection

NFPA 24 - Installation of Private Fire Service Mains and their

Appurtenances

NFPA 30 - Flammable and Combustible Liquids Code

NFPA 72 - National Fire Alarm Code



1.6 Conflicting Requirements

In case of conflict between documents, the order of priority shall be :

a) Purchase Order or EPC Contract as Applicable

b) Data Sheets or item specific written requirements

c) This Specification

d) Other Company Specifications

e) API and NFPA standards

f) Other Referenced Publications

g) Purchaser’s or Vendor’s Standards

The Vendor shall obtain written approval from Purchaser before proceeding with work affected by a conflict.

2. GENERAL SAFETY AND FIRE PROTECTION PHILOSOPHY

2.1.1 The general safety and fire protection philosophy recognizes following main activities :

Safeguarding of personnel.

Safeguarding of plant.

Safeguarding of production regularity.

Safeguarding of the environment.

2.1.2 To accomplish these safeguarding activities two steps will be followed :

Minimize loss of confinement, i.e. releases of flammables to the atmosphere.

Minimize the consequences of a loss of confinement i.e. explosion, fire, toxic releases.

2.1.3 The minimization of the consequences of a loss of confinement (the main topic of this document) is achieved by the following main means :

Providing a safe plant layout by separation of hazards (e.g. leak sources from ignition sources), building and drainage of liquid storage and spill risk areas, separation of hazard units to prevent escalation and by inclusion of adequate access and escape routes.

Fire/gas detection and shutdown / blow down systems designed to isolate and render safe sections of the plant involved in a hazardous occurrence.

Fire fighting systems designed to minimize the effects of fire either by fire extinguishing or exposure protection.



2.1.4 Essentially a manual intervention policy will be followed for defining fire fighting system and equipment requirements. This means that site personnel will carry out most fire fighting tasks, using fixed and mobile appliances in conjunction with the fire main system. Fixed fire protection systems supplied from the fire main will be used where manual application is not adequate or may be hazardous to the fire fighters. Independent fixed fire protection systems using gaseous agents will be used where they are the most effective and appropriate means of fire suppression, e.g. for gas turbine enclosures.

2.1.5 Safety and fire protection system provision and design will make use of codes and recommended practices as the main basis.

3. FACILITY LAYOUT

3.1 Basic Principles

3.1.1 In designing the layout of the plant, including associated facilities, the Contractor shall consider the following :

Efficiency / Operability

Safety

3.1.2 The principle of efficiency / operability ensures that :

The process flow is arranged in a logical manner.

Equipment and controls are arranged to facilitate operation.

Ease of maintenance is provided.

Cost are minimized.

3.1.3 The following are the main aspects to be considered for a safe plant layout :

Limited inventory in a process area.

Access / escape for fire fighting.

Separate ignition sources from likely leak sources.

Limit fire water requirements.

Limit fire spread caused by hazards escalating from one plant area to adjacent ones.

3.1.4 The safety criteria for initial plant layout are taken from Company requirements, from relevant codes and standards and from recommended good practice.



3.2 Detail Requirements

3.2.1 For the Gas Plant Facilities, the separation distances between equipment within process units and between process units and other plant items / areas shall be based on the distances given in Appendix I.

3.2.2 Flares shall be located to meet the radiation levels given in API RP 521 and at least 300 ft from process, utility or offsite facilities.

Allowable Thermal Radiation Flux Level (API RP 521 A)(For Flare Design Only)

Permissible Design Level (K)Conditions

Btu/Hr/Ft2 kW/m2

5,000 15.77Heat intensity in structures and in areas where operators are not likely to be performing duties and where shelter from radiant heat is available (for example, behind equipment)

3,000 9.46

Valves of K at design flare release at any location to which people have access (for example, at grade below the flare of a service platform of a nearby tower), exposure should be limited to a few seconds, sufficient for escape.

2,000 6.31Heat intensity in areas where emergency actions lasting up to 1 minute may be required by personnel without shielding but with appropriate clothing.

1,500 4.73Heat intensity in areas where emergency actions lasting several minutes may be required by personnel without shielding but with appropriate clothing.

500 1.58Value of K at any location where personnel with appropriate clothing may be continuously exposed.

3.2.3 The direction of the prevailing wind shall be considered in locating the control building, offices, workshops, etc.

3.2.4 Escape and access ways will serve both personnel and fire teams (together with their equipment such as fire fighting vehicles and trailers). The minimum clearances to be provided in the design shall be in accordance with the following unless approved otherwise by the Company.

Description Min. Clearance

Escape routes Headroom 7’ – 6” Width 4’ – 0”Main Access Ways Headroom 7’ – 6” Width 5’ – 0”Maintenance equipment access Headroom 7’ – 0” Width 3’ – 6”



Description Min. Clearance

Maintenance walkways Headroom 7’ – 0” Width 3’ – 0”Equipment Clearances around equipment shall be in accordance with accepted Engineering and layout practice taking into account clearances stated above, space availability, operability, maintenance and safety consideration. (see Appendix I)Piping Over roadways 16’ – 0” Beneath main pipe ways 12’ – 0”

3.2.5 There shall be two escape routes from rooms, platforms and confined work areas. However only a single escape route is required from small rooms, platforms or confined work areas i.e. where maximum distance to the point of escape (door) is 16 ft.

3.2.6 Where frequently daily access to elevated equipment is required, stairways rather than ladders shall be provided.

3.2.7 Where ladders are used they shall have non-slip rungs and safety bars at entry points. Ladders on tall structures (e.g. columns) shall have staggered intermediate platforms and safety cages shall extend to the handrails of these intermediate platforms.

4. FIRE PROTECTION SYSTEMS

4.1 General

4.1.1 The basic principle to be applied to the design of fire protection systems is manual intervention. Generally fire extinguishing and equipment protection will be manually applied. In those instances where manually applied fire fighting is not adequate then fixed / automatic systems shall be provided.

4.1.2 The Fire and Gas Detection System is designed to give warning of hydrocarbon releases to the atmosphere and fires. Such warnings will initiate response by each facility fire team.

4.1.3 General requirements for fire and gas detector location and the associated control system and logic are contained in the Project Specification for Instrumentation General Requirements, document number PS-1100-ICC-001.

4.1.4 Fire detection systems shall be located in all administration/camp buildings not protected by automatic sprinklers. Smoke detectors shall be installed in all sleeping quarters.



4.1.5 Fire alarms for the camps and offsite shall be transmitted to the fire alarm panel in the control room from sub alarm panels in the fire station and senior staff house building.

4.1.6 Fixed fire protection systems will be used where rapid (i.e. automatic) system operation is necessary to achieve the fire protection aim (a typical example being gas turbine protection).

4.1.7 Passive fire protection will be provided to maintain the integrity of structures and vessel supports whose collapse could lead to unacceptable fire escalation or damage equipment critical to the operation of the plant.

4.2 Fire Water System

4.2.1 The fire water systems shall comprise of the following main items :

Fire water storage tanks.

Centrifugal fire pumps.

One jockey pump to pressurize the fire main.

Electrical and/or diesel driven pumps and filtration equipment to supply the fire water storage tank from the water source, well or river.

Fire ring main distribution system complete with sectioning valves, hydrants/monitors and hose cabinets.

A “Layout Drawing of Fire Fighting Equipment” must be generated to fully define the requirements for plant. Pressure and flow calculating shall be performed to define line sizes for fire water systems.

4.2.2 Fire Water Storage Tanks

4.2.2.1 The fire water storage tank shall also be used to store water for the utility water system. The suction for the utility water pumps shall be taken from a tank wall nozzle located at high level so that the storage capacity below the off take is sufficient for fire fighting requirements.

4.2.2.2 The storage capacity is to be worked out as follows :

2 hours storage for maximum flow from one fire pump (i.e. at 100% of design point) plus 2 hours of diesel engine cooling water, for the Gas Plant and offsite/camp.

Minimum 30 minutes storage for utility water.

No allowance for supply pumped from the river.

4.2.2.3 The tank shall be in accordance with the requirements of NFPA 22.

4.2.3 Fire Pumps



4.2.3.1 Two 100% rated fire pumps will be provided at the Gas Plant for the process area including off sites and/or camp area. The pumps, which will take suction from the storage tank, will be the horizontal centrifugal type.

4.2.3.2 Electrical and diesel pumps will be provided at the Gas Plant. The pumps, drivers, starting/control systems and all ancillary equipment shall conform to the requirements of NFPA 20. As a minimum the starting / control system shall be FM Approved or UL Listed.

4.2.3.3 Fire pump starting shall be arranged for both manual and automatic starting.

4.2.3.4 Remote manual starting push buttons shall be provided in the Control Room at the Gas Plant. Start facilities shall also be provided local to each fire pump.

4.2.3.5 Automatic starting of the fire pump shall be as a result of low fire main pressure. Individual pressure sensors shall be provided for each fire pump.

4.2.3.6 The electrically driven fire pump shall be the designated lead pump and shall start when the fire main pressure falls to 120 psig. (A short time delay shall be provided to prevent fire main surges and pressure fluctuations from spuriously starting the pump).

4.2.3.7 The diesel driven pump shall be the designated back-up pump. It shall automatically start if the lead pump fails to start or maintain the necessary fire main pressure. The start pressure shall be 110 psig, with a 15 second time delay.

4.2.3.8 Stopping of the fire pumps shall only be possible at the local control panel of the fire pumps.

4.2.3.9 A fire pump test line shall be provided (with flow returned to the storage tank) to allow for periodic testing of the hydraulic performance of the pumps.

4.2.4 Jockey Pumps

4.2.4.1 One electricity driven jockey pump shall be provided to pressurize the fire ring main system and to supply utility water for offsite / camp. Jockey pump shall be continuously operated to maintain pressure of the ring main.

4.2.4.2 The pump shall take suction from the utility water connection of the storage tank so that excessive camp utility water usage would not take firewater reserve. Return flows shall also be directed there. The pump and associated controls shall be designed to maintain a pressure of 140 psig in the ring main.

4.2.5 Fire Water Ring Main

4.2.5.1 A fire water ring main of 8” diameter shall be provided throughout the Gas Plant to provide fire water to hydrants, monitors and fixed fire fighting equipment. A 6” diameter ring main shall be provided at the camps.



4.2.5.2 The fire main shall be buried and suitably protected at road crossings. It shall arranged as a series of connecting loops to ensure a reliable supply of fire water is available even if sections are damaged or isolated for maintenance. At each junction, valves shall be provided to allow sections of the ring main to be isolated.

4.2.5.3 Sections of looped mains without junctions shall be provided with isolating valves at 500 ft intervals. Sufficient valves shall be provided so that no more than three monitors and/or hydrants need be isolated, in the event of main damage.

4.2.5.4 The pump/ring main system shall be capable of supplying at 100 psig the most hydraulically onerous demand with the storage tank fully drawn down. Checks shall be made (by hydraulic calculation) to ensure there is no significant performance degradation if parts of the ring main are isolated.

4.2.5.5 Facilities shall be provided to allow the ring main system to be flushed. (Refer to NFPA 14, 15, 24 for the flushing basis). Hydrants/monitors may be used for this purpose provided that it can be justified by hydraulic calculation.

4.2.5.6 The impact of transients (water hammer) due to pump and valve operation shall be fully evaluated and any design/operating constraints established.

4.2.5.7 All valves on the fire main and on lines to fire protection equipment which are provided basically for maintenance isolation shall be locked open.

4.2.5.8 Hose box shall be constructed of galvanized CS painted and clearly marked as “Fire Hose Box”. It shall be in appropriate place in the fire water ring.

4.2.6 Hydrants

4.2.6.1 Fire water mains shall be provided with permanent pillar hydrants with dual valved outlets at a spacing suitable to give adequate coverage of the facility.

4.2.6.2 Hydrants shall be readily accessible from roads and be located in such a way that possible damage by road traffic will be minimized.

4.2.6.3 The location shall not be less than 5 ft from the edge of the road, and at least 30 ft from road crossing or sharp road curves and 50 ft from buildings or other structures.

4.2.6.4 Hydrant couplings shall be Storz. Hydrant outlets shall be provided with chained plugs.

4.2.6.5 Painting shall be in accordance with Painting specification.

4.2.7 Fire Monitors

4.2.7.1 Manually operated fire monitors shall be located on the periphery of the process areas and adjacent to the condensate storage tank bund. Locations shall be determined to optimize coverage of hydrocarbon process equipment eq. pumps, vessels.



4.2.7.2 Monitors shall be rated 500 US gpm at 135 psig inlet pressure. Monitors located around the condensate storage tank and where liquid pool fires are a likely hazard will be provided with integral foam proportioners, dip-tubes, aspirating nozzles and foam spreaders. Monitors for water only duty shall have adjustable jet/fog nozzles.

4.2.7.3 Monitors and hydrants may be combined in one unit.

4.2.7.4 All monitors shall have clamps to enable them to be locked in position and shall have a shielding spray for the protection of personnel operating them.

4.2.8 Fixed Fire Extinguishing Systems

4.2.8.1 Fixed systems designed to extinguish fires will be provided, typically :

Gaseous extinguishing systems (for gas turbine enclosures).

Sprinkle systems in warehouses, workshops, administration building (Gas Plant) and administration/camp buildings : mess halls, kitchens, laundry, recreation halls etc.

The design and installation of fixed water spray systems shall conform to NFPA 15.

4.2.8.2 Gas turbines, housed within enclosures, are used for power generation. A fixed, automatic CO2 system will be provided for fire suppression within these enclosures. The system will be designed in accordance NFPA 12 and will have the following features :

Extended soak time to allow hot surfaces to cool thus preventing re-ignition.

Positive means of system lock off to allow safe entry to the enclosure.

Pre-alarm and system status information at enclosure access points.

Systems to be arranged with primary and secondary banks, each capable of a single shot.

4.2.8.3 The CO2 systems will be supplied as integral parts of the generator packages.

4.2.8.4 Sprinkle systems shall be provided to protect workshops, warehouses, critical buildings in the offsites area and main common buildings in camps. Sprinkle heads shall also be provided to protect the diesel powered fire pump. (For specific building and area to protected by sprinkle system, refer to the specification PS-1100-ICC-002).

4.2.8.5 Sprinkle systems shall be designed in accordance with NFPA 13 and specialized equipment shall be UL Listed or FM Approved. Operation of each sprinkle system shall generate a local alarm and alarms in the control room and fire station.

4.2.9 Portable and Mobile Fire Fighting Equipment



4.2.9.1 Hose cabinets containing fire fighting equipment for use with hydrants shall be located adjacent to hydrants or groups of hydrants. The equipment contained shall be sufficient to allow two hydrant hose streams to be operated and will be typically :

2 off 75 ft of 1 ½” collapsible hose.

2 off 75 ft of 2 ½” collapsible hose.

2 off jet/fog/off nozzles.

Quick connections system.

Adapters and wrenches.

Axe.

4.2.9.2 In areas where a significant pool fire risk exists additional equipment for foam making shall be provided, typically :

2 off foam branches (aspirating).

2 off inline proportioners with pick-up tubes.

4 off 5 US gal containers of foam.

4.2.9.3 Fire extinguisher for first aid fire fighting shall be provided throughout the process and offsite areas of the plant.

4.2.9.4 Extinguisher shall be located at clearly visible locations on the way to/from likely fire areas and enclosures. Hand portable extinguishers shall be located in boxes in outside areas and on wall brackets/hooks in inside areas.

4.2.9.5 The following extinguishers shall be provided as a minimum :

Pressurized Water or Warehouses, workshops, offices, mess.

ABC Dry Chemical Powder/accommodation areas.

Dry Chemical Powder Process areas, pump areas, diesel engine spaces,

electrical/instrument equipment rooms, kitchen

areas (BC rated). CO2 Instrument and electrical equipment areas.

4.2.9.6 Larger, wheeled CO2 and dry powder extinguishers shall be located outside enclosures housing turbines, diesel engines and electrical equipment.

4.2.9.7 A single foam type shall be used throughout the plant. The foam concentrate shall be 3% AFFF and alcohol resistant. The foam shall conform to MIL-F-24385C and be FM Approved, UL Listed or acceptable equivalent.

4.2.9.8 Protecting clothing *1) for use by the fire team shall be provided in the fire station.

Note *1) : These are scope of provisional work (by Gulf).



4.2.9.9 All portable fire extinguishers shall be of cartridge or stored pressure type, designed for controlled discharge capability.

4.3 Passive Fire Protection

4.3.1 General

4.3.1.1 Passive fire protection (PFP) shall be provided for critical structural members and equipment supports.

4.3.1.2 The degree of passive fire protection to be used will depend initially on the fire type expected. Gas jet fires are the most likely type. Liquid pool fires could occur in areas where condensate or glycol are handled.

4.3.1.3 For protection of structural members and equipment the PFP is specified by a combination of protection duration (i.e. maximum fire duration) and protect material maximum core temperature (above which necessary strength is lost).

4.3.1.4 PFP shall be evaluated for use within the “Fire – Exposed Envelope” as defined in Section 2 of API Publication 2218. Items to be protected shall be generally as defined in Section 3 of API 2218.

4.3.2 Materials for passive fire protection

4.3.2.1 Materials shall be tested to UL 1709 and have a proven record in industrial fire proofing service.

4.3.2.2 The fire performance of the systems selected must be certified by a recognized certifying/approvals body. The necessary certification must be based on a hydrocarbon type fire test (e.g. the Rapid Temperature Rise test in UL Subject 1709).

5. PERSONNEL SAFETY AND PLANT SECURITY

5.1 Personnel Safety Equipment

5.1.1 A stretcher, blanket and first aid box *2) shall be provided in or adjacent to the Control Room.

5.1.2 Eyewash and safety showers shall be provided in proximity to the battery storage area and at other locations in the plant where accidental spillage of chemicals could occur.

5.1.3 Safety signs and notices shall be provided throughout the plant in accordance with recognized codes and standards. These shall be in both Indonesian and English language.

5.1.4 Walkways across pipes and working platforms on vessels and equipment shall be provided with non-slip surfaces.



5.1.5 Personnel protection shall be provided, in accessible congested areas, against contact with hot surfaces (> 150 0F).

5.1.6 Portable flammable gas, oxygen and H 2S detectors *2) shall be provided, stored in the control room, to enable personnel to check gas levels after failure of the gas detection system or total shutdown of the plant, or where abnormal gas accumulations have occurred, and to assure safety during maintenance/repair activities. The oxygen detector shall be used to check vessels, tanks prior to maintenance.

5.1.7 An Ambulance *2) shall be provided and equipped as detailed by the Company.


5.2 Noise Control

5.2.1 The following area noise limits generally shall be applied :

Area Noise Limit dB (A)

Control Room, Laboratory 60Workshop 70All other work areas within the plant 85

5.2.2 If the 85 dB (A) limit cannot be achieved in certain areas (e.g. Power Generation Area) these areas shall be designated as restricted and appropriate warning signs posted.

5.2.3 To meet the above limits for personnel, a maximum sound pressure level shall be specified for noise generated by equipment as follows :

85 dB (A) at a minimum distance of 3 ft from the equipment. (Refer to noise specification on relevant data sheet or Duty Specification).

5.2.4 A breathing air compressor, bottles and breathing apparatus (for four persons) *3) shall be installed in the fire station.

5.2.5 The flare tip shall be designed to ensure that, under maximum design flare rate conditions, noise levels at the facility fence will not exceed those specified by the Indonesian authorities.




Appendix 1


Spec. Safety and Fire Protection - SJB

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