Fire Fighting System Requirements/Design for LPG Bottling Plants

K. NagamalleswaraRao1*, Chellinkula Pavan Kumar2

1
Centre for Disaster Mitigation and Management, Vellore Institute of Technology, Vellore,
Tamil Nadu, India
2
Chellinkula Pavan Kumar, Keppel Shipyard Ltd, Singapore
*nagamalleswara.rao@vit.ac.in
Abstract

Because of the hazardous nature of liquefied petroleum gas (LPG), LPG bottling plants are
located away from populated areas. With the progress of time, these plants are surrounded by
residential localities or settlements in the absence of any statutory regulations prohibiting
their construction. Large quantities of highly inflammable products stored in the bottling
plants pose a safety risk to the plant as well as to the surrounding environment. This problem
demands the installation of elaborate in-built fire protection facilities at the LPG bottling
plants. The possibility of boiling liquid expanding vapor explosion (BLEEVE) is the most
hazardous situation in the LPG vessel. This usually takes place when the vessel is subjected
to an external fire. In this situation, the un-wetted portion of the shell occupied by vapor
space gets overheated and fails even at the operating pressure. This overheating of the LPG
tank in the vapor space region should be controlled. A passive measure likes fireproofing/
insulation or fire retardant coating will protect in the initial period of fire which is very
crucial. This will give some breathing time for activating other firefighting measures like the
starting of pumps, organizing people, the opening of valves, etc. This will also take care of
automation failure wherever it is provided. Designing an effective firefighting system helps
in mitigating these disasters. In this context, this original research work deals with the
minimum requirements of fire protection facilities at LPG bottling Plants. The design
calculations followed the Oil Industry Safety Directorate (OISD) safety standards. The
firefighting system design procedure presented in this work is useful for process safety
engineers to handle fire accidents effectively in LPG bottling plants.

Key words: BLEEVE, Disaster, Fire accident, Firefighting system, LPG plant, OISD.

1. Introduction

Worldwide consumption of LPG gas is increasing in a rapid pace. To meet the demand
nations are starting their new bottling plants or going for enhancing the existing LPG bottling
plants capacity [1,2]. Since LPG is a highly inflammable gas the scope for fire accidents is
also high. Because of its highly inflammable nature the number of accidents is also increasing
worldwide. These accidents lead to human and property losses. To minimize these losses
preparation of disaster management plan is necessary and firefighting is one of the resources
in disaster management plan [3]. For the safety of the plant it is necessary to identify the
hazards associated with the bottling plant. LPG leak will create several hazards like fireball,
jet fire and vapour cloud explosion [4]. The information from the open literature says that the
scope for the fire accidents is more in LPG bottling plants. In this context designing a fire
fighting system is crucial to prevent or mitigate the industrial disasters in LPG plant.

In LPG bottling plant storage section, gantry section and pump house section occupies the
major part of the plant. More risk hazards are present at these sections. Providing the
firefighting system for these sections minimizes the accidents. Fire protection system for
LPG bottling plant contains fire water storage tanks, fire water pump house (shed), fire
hydrant system, MV spray system, fire extinguishers, deluge valves, isolation valves and the
manual call points. Implementing the appropriate design procedures at the initial design stage
itself improves the efficiency of the firefighting system [5]. This objective inspired this
research work to design firefighting system for a LPG bottling plant. This research is mainly
focussing on water demand calculations for gantry, pump house and the storage tank or LPG
bullets.

2. Theory

The design basis for this research work is LPG bottling plant containing loading/unloading
gantry, pump house and the storage tank or the LPG Bullet. Loading/unloading gantry
approximate size is 48 meter length and 16 meter wide. Pump house size is 15 meter long
and 10 meter wide. Storage vessel or the LPG bullet size is 700 Metric Tonnes. Firefighting
system for this plant needs the water demand calculations for the each section of the plant.
Summation of all sections water demands, gives the total water demand for the entire LPG
bottling plant. Based on the water demand calculation, the size of the nozzles required and
their locations in each section of the plant are estimated.

3. System Description

3.1 Fire Hydrant System

The yard hydrants and monitors will be provided around the periphery of the LPG Storage
facility at minimum distance of 15 meter from the face of the building and will be placed
maximum 30 meter distance between hydrants and monitors. The pipelines shall be above
ground and wherever above ground piping is not feasible, the pipe shall be laid 1 meter below
ground level with Hume pipe support for road crossing. Each hose box contains two number
15 meter long hose with branch pipe and brass nozzle. Except where impracticable, all
hydrant outlets shall be situated 1 meter from the normal ground level.

The stand posts shall be 100 mm for double-headed hydrants and 150 mm diameter for water
monitors. Only oblique hydrants conforming to IS: 5290 with outlets angled towards ground
shall be used. Minimum pressure of 5.25 bar shall be ensured at the remotest yard hydrant
point and top most landing valve. The hydrant system mainly consists of Double Headed
hydrant valves, Fixed type water monitor and sectional valve etc. Stand pipes shall be tapped
from the ring mains. The mains shall be charged with water to the system design pressure of
Minimum 7 kg/cm2 to be tapped from existing hydrant ring main at the strategic location.

3.2 Automatic Water Spray System

The following design parameters are described for the medium velocity water spray system in
various areas in order to ensure adequate protection for the respective occupancies.

Table 1. LPG Pump room specifications

Parameter Suggestions
Design Standard OISD-144
Hazard Classification High Hazard
Type of System Medium Velocity Water Spray System
Design Density 20.4 lpm/m2
Minimum Operating Pressure of Spray
1.4 bar
Nozzle
Velocity Considered up to DV 5 m/s

Table 2. MSV specifications

Parameter Suggestions
Design Standard OISD-144
Hazard Classification High Hazard
Type of System Medium Velocity Water Spray System
Design Density 10.2 LPM/m2
Minimum Operating Pressure of Spray
1.4 bar
Nozzle
Velocity Considered up to DV 5 m/s
 Table 3. Loading/Unloading Gantry specifications

Parameter Specifications
Design Standard OISD-144
Hazard Classification High Hazard
Type of System Medium Velocity Water Spray System
Design Density 10.2 LPM/m2
Minimum Operating Pressure of Spray
1.4 bar
Nozzle
Velocity Considered up to DV 5 M/s

K-factor selection of MV nozzle shall be provided in the detailed design drawing based on
the design density considered in the above table 3. Fire Detection line with detector (QBD)
shall be pneumatic type with minimum pressure of 2-3 kg/cm 2. The Airline shall be tapped
from existing line at suitable location.

3.3 System Operation

Initially, the system shall be charged with water to the system design pressure. The system
pressure is expected to fall down due to minor leakages. When the pressure drops to the
predetermined pressure, the respective pressure switch shall sense the same and send the
signal to the MCC & control panel. Immediately, Jockey pump shall be switched on to
elevate the system pressure to the normal level. As soon as the normal system pressure is
reached, the respective pressure switch shall send the signal to the MCC & control panel to
switch off the jockey pump. Thus the normal system pressure shall be maintained by the
jockey pump.

3.4 Hydrant System

In the event of fire, when one or more hydrant valves/ Water Monitor are opened, the
pressure in the hydrant main shall drop due to the resulting flow and at a low pressure in the
hydrant main, the jockey pump shall start automatically. When the jockey pump cannot meet
the required flow rate and pressure the main hydrant pump into operation immediately. If
main firewater pump fails to start due to extraneous reasons, the standby pump will come into
operation through the respective pressure switch at the pre-set pressure.
As soon as any one of the firewater pump comes into operation the jockey pump will be
switched-off by the interlock provided in the MCC. The firewater pumps (main and standby)
will be switched off manually after ensuring that the fire is extinguished completely.

3.5 Automatic Water Spray System

In the event of fire, a fire signal shall be provided from the Local Control Panel to Deluge
valve for auto operation of MVWS system. When detector detects the fire through pneumatic
actuator (solenoid valve) is installed in the downstream of detection line, PORV and
emergency release connections.

This will drain the water from upper chamber of deluge valve to atmosphere resulting in loss
of pressure on the top chamber of deluge valve. Due to which the diaphragm of deluge valve
shall imbalance. As result the water rushes from upstream of DV to main spray network and
comes out through open spray nozzles.

To operate the system locally, a manual emergency release has been provided in deluge valve
as follows:

1. A tapping from the trim ends in a drain valve provided for "Emergency Release".
2. Local push button in the Deluge valve local control Panel.

Operating the valve will release the pressure above the deluge valve clapper and then the
system will operate as just described earlier.

3.6 Portable Extinguishers

1. Above ground storage tanks/bullets shall be fitted with one 9-12 kg dry chemical
powder extinguisher of adequate fire class each.
2. Pump stations shall be fitted with one 9-12 kg DCP extinguisher for every 2 pumps
and one wheeled 50 kg DCP extinguisher for every 5 pumps having suitable mobile
firefighting equipment available for first intervention and prevention of escalation of
fires.
3. Truck racks stations must be fitted with one 9-12 kg DCP extinguisher for every 2
lanes and one wheeled 50 kg DCP extinguisher for every 5 lanes to allow first
intervention.
 4. Fire water pump houses must be fitted with one 9-12 kg DCP extinguisher for every 2
pumps and one 5 kg CO2 extinguisher
5. Fire water pump houses must be fitted with one 9-12 kg DCP extinguisher for every 2
pumps and one 5 kg CO2 extinguisher
6. All other buildings shall be fitted with DCP and CO2 extinguishers as defined in the
Building Specifications

4. Calculations of Fire Fighting system

4.1 Water demand and spray nozzle calculations for LPG storage vessels

4.1.1 Water demand calculation for storage vessel

Volume of one storage tank in the LPG bottling plant is 700 MT. Water demand calculation
needs the values of tank length and diameter. These parameters are calculated based on
length to diameter (L/D) ratio of the tank. L/D ratio is considered as 6. Volume of the tank is
calculated using equation (1)

D2
V =π
4 ( )
L(1)

D2
700 m3=π ( )
4
L

By substituting L/D as 6 and after mathematical manipulations diameter (D) value calculated
is 5.296 m and the corresponding length (L) of the tank is 31.7763 meter. Then the surface
area of the tank calculated from equation (2).

D2
( )
A s=( πDL ) +2 π
4
(2)

Total tank surface area As is 572 m2. As per OISD-117 the cooling water spraying rate for
storage tanks is 3 lpm/m 2. Then the cooling water requirement from equation (3) is 1717
lpm.

Cooling water requirement=Cooling water spraying rate∗Total surface area( A s)(3)

For cooling time four hours total cooling water requirement for one storage tank is equal to
412173 liter. .
4.1.2 Fire water requirement for each nozzle

For the calculation of design flow rate of cooling water 20% safety margin is considered.
Then the extra flow rate of the cooling water becomes the summation of cooling water
requirement i.e 1717 and 20% of its value. Then the design flow rate of cooling water
becomes 2061 lpm. To calculate the water requirement for each nozzle numbers of nozzles
are needed. This can be obtained once the flow rate from each nozzle (Q) is known. For that
equation (4) is used.

Q=k∗ √ ∆ P (4)

k factor is 30 lpm/bar0.5. ∆ P is pressure drop across each nozzle i.e 1.5 bar. Then from
equation (4) flow rate from each nozzle (Q) is = 30 (lpm/bar 0.5) * √ 1.5 ¯¿ ¿ = 36.74 lpm.
Number of nozzles required is calculated using equation (5).

Design flowrate of Cooling water

Number of Nozzlesrequired= (5)
equation(4)

i.e = 2061/36.74 = 56

fire water requirement of each nozzle is calculated from equation (6).

Design flow rate of cooling water

Fire requirement of each nozzle= (6)
equation(5)

Fire water requirement of each nozzle = 2061/56 = 36.71 lpm.

4.1.3. Distance between nozzles

Operating pressure of the upstream nozzle is considered as 3 barG, pressure drop across
nozzle is 1.5 bar. Selected k factor from the vendor information is 30 lpm/bar 0.5. Number of
nozzles selected based on radial spray distance is 56. The distance between the nozzles is
calculated from equation (7).

2∗Tank length
Distance between the nozzles= (7)
Number of Nozzles selected

= 2* 31.7763/56 = 1.134 meter.

(Note: Recommended operating pressure across the nozzle is in between 1.4 and 3.5
kg/cm2.g).

4.2 Water demand and spray nozzle calculations for loading/unloading Gantry

4.2.1 Water Demand calculation for Gantry

Gantry length is 48 meter and its breadth is 16 meter. Gantry area is calculated from equation
(8) and it is 768 m2.

Gantry area=length∗Breadth(8)

From OISD-117 for Gantry cooling water spraying rate is 10.2 lpm/m 2. From equation (3)
cooling water required for gantry is 7834 lpm. For one hour it is 470040 liter and for four
hiurs of time it becomes 1880.16 KL.

4.2.2 Fire water requirement for each nozzle

For the calculation of design flow rate of cooling water 20% safety margin is considered.
Then the extra flow rate of the cooling water becomes the summation of cooling water
requirement i.e 7834 lpm and 20% of its value. Then the design flow rate of cooling water
becomes 9400 lpm. To calculate the water requirement for each nozzle numbers of nozzles
are needed. This can be obtained once the flow rate from each nozzle (Q) is known. For that
equation (4) is used. The value of flow rate from each nozzle (Q) is 36.74 lpm. Number of
nozzles required calculated from equation (5)

= 9400/36.74 = 256 nozzles.

Fire water requirement of each nozzle is calculated from equation (6).

=9400/256 = 36.74 lpm.

4.2.3. Distance between nozzles

Operating pressure of the upstream nozzle is considered as 3 barG, pressure drop across
nozzle is 1.5 bar. Selected k factor from the vendor information is 30 lpm/bar 0.5. Number of
nozzles selected based on radial spray distance is 256. The distance between the nozzles is
calculated from equation (9).

2∗Gantry width
Distance between the nozzles= (9)
Number of Nozzles selected
 = 2*16/256 = 0.125 m

Here the criteria for recommending the operating pressure range is it should be between 1.4
and 3.5 kg/cm2.g.

4.3 Water demand and spray nozzle calculations for Pump house

4.3.1 Water demand calculation for Pump house

Pump house length is 15 meter and its width 10 meter. Pump house area is calculated from
equation (8) and it is 150 m2.

Pump house area=length∗Breadth(10)

From OISD-117 for pump house cooling water spraying rate is 10.2 lpm/m 2. From equation
(3) cooling water required for gantry is

= 150*10.2 = 1530 lpm

For one hour it is 91800 liter and for four hours of time it becomes 367.2 KL.

4.3.2 Fire water requirement for each nozzle

For the calculation of design flow rate of cooling water 20% safety margin is considered.
Then the extra flow rate of the cooling water becomes the summation of cooling water
requirement i.e 1530 lpm and 20% of its value. Then the design flow rate of cooling water
becomes 1836 lpm. To calculate the water requirement for each nozzle numbers of nozzles
are needed. This can be obtained once the flow rate from each nozzle (Q) is known. For that
equation (4) is used. The value of flow rate from each nozzle (Q) is 36.74 lpm. Number of
nozzles required calculated from equation (5)

= 1836/36.74 = 50 nozzles.

Fire water requirement of each nozzle is calculated from equation (6).

=1836/50 = 36.72 lpm.

4.3.3. Distance between nozzles

Operating pressure of the upstream nozzle is considered as 3 barG, pressure drop across
nozzle is 1.5 bar. Selected k factor from the vendor information is 30 lpm/bar 0.5. Number of
nozzles selected based on radial spray distance is 50. The distance between the nozzles is
calculated from equation (9).

2∗Pump house width

Distance between the nozzles= (11)
Number of Nozzles selected

= 2*10/50 = 0.4 m

5. Total water demand for the LPG bottling plant

Total water demand for the plant is the summation of water demands of storage vessel, gantry
and the pump house. Then the total water demand is

Total water demand=Storage Vessel water demand +Gantry water demand+ Pump house water demand (12)

= 412.173 kl+ 1880.1 kl +367.2 kl

= 2659.473 KL

6. Fire Detection Systems

1. Pump stations and large manifolds that are not directly visible from the control room,
shall be fitted with fire detection systems or covered by permanent CCTV
surveillance.
2. Closed fire water pump houses shall be fitted with smoke detectors or other fire
detection systems.
3. All electrical substations, motor control centres, laboratories/sample storage rooms,
control rooms, server rooms and offices shall be provided with smoke detection
systems
4. Terminals which are unmanned at night time shall at least link required detection
systems to a 24/7 emergency response centre (e.g. fire brigade, service provider or
CCR of another terminal.

7. Conclusions
The Fire Fighting calculation procedure followed in this work is developed based on the
OISD-117 standards (Oil Industry Safety Directory). This procedure can be recommended
for the fire water system design for buildings, other industries, schools, colleges, commercial
complexes or any other civil structures also. This research study is useful for Fire Fighting
system design engineers and for safety engineers in designing the Fire Fighting system for
LPG bottling plants.
Acknowledgement

We are grateful to Vellore Institute of Technology (VIT University), India for providing the
necessary facilities for the successful completion of this research work.

References

[1] Bruce N, de Cuevas RA, Cooper J, Enonchong B, Ronzi S, Puzzolo E, MBatchou B, Pope
D. The Government-led initiative for LPG scale-up in Cameroon: Programme development
and initial evaluation. Energy for Sustainable Development. 2018 Oct 1;46:103-10.

[2] Dalaba M, Alirigia R, Mesenbring E, Coffey E, Brown Z, Hannigan M, Wiedinmyer C,

Oduro A, Dickinson KL. Liquified Petroleum Gas (LPG) Supply and Demand for Cooking in
Northern Ghana. EcoHealth. 2018 Dec 1;15(4):716-28.

[3] Rao TV. Disaster Management Plan for LPG Bottling Plants. Fire Engineer.
2009;34(1):29-30.

[4] Bariha N, Srivastava VC, Mishra IM. Incident analysis of various sections of a liquefied
petroleum gas (LPG) bottling plant. Indian Chemical Engineer. 2019 Nov 22:1-2.

[5] Wang YC, Marsden J, Kelly M. Challenges of fire fighting in fire engineered built
environment. Procedia Engineering. 2011 Jan 1;11:583-92.

[6] Shirvill LC. Efficacy of water spray protection against propane and butane jet fires
impinging on LPG storage tanks. Journal of Loss Prevention in the process Industries. 2004
Mar 1;17(2):111-8.

ADD OISD, NFPA standards as references