GAIL (India) Limited

Gas Processing Unit, Gandhar, Gujarat

A PROJECT REPORT
ON
“Review and Adequacy Check of Water and Extinguisher Based Fire
Protection Systems at GPU, Gandhar”

Submitted By:
Arun Deswal (अरुण दे सवाल) (CPF-17993)
Executive Trainee (Fire & Safety)
 ACKNOWLEDGEMENT

I would like to express my special thanks of gratitude to Sh. Hitendra Patle DGM
& HoD (F&S) for his sincere efforts towards guiding, mentoring at each step and
providing the required resources for learning the departmental jobs as well as and
procedures. I would also like to extend my sincere gratitude to Sh. Mukesh Singh
Rathore CM (F&S) and Sh. P R Jakhar for their help and guidance in inculcating
and executing new jobs which in turn helped me in my overall development. This
would not have been possible without their continuous support and supervision at
all the times.

I would also like to extend my heartfelt thanks to all the executives in the
department for their support and guidance, especially Sh. K K Surati, Sh. H S
Gautam, Sh. V S Patil and Sh. J U Dandane for helping me get through all the
challenges faced while completing the project, learning new jobs in the field.

I would also thank all the staff and other members of the department for their
sincere support, knowledge sharing and guidance. All this will surely help me in
achieving new endeavors and creating milestones.

(Arun Deswal)
ET (F&S)
 CONTENT

Page No

1 Introduction 1
1.1 About GPU, Gandhar 1
1.2 Storage Facility 1
1.3 Loading Facility 1

Review and Adequacy Check of Water Based Fire Protection Systems of GPU,
2 2
Gandhar
2.1 Fire Water Network System 2
2.2 Fixed Water Spray System 7
2.3 Mobile Fire Protection Equipments 7
2.4 Foam Based Fire Protection for Floating Roof Tank 8

Review and Adequacy Check of First Aid Fire Protection Systems

3 8
of GPU, Gandhar
3.1 Fire Aid Fire Extinguishers (Dcp & Co2) at all Hazardous Locations 8-10

LIST OF FIGURES
 Page
No
Fig. 2.1 Fire Water Network and Protection system Layout of GPU, Gandhar 6

Fig. 2.2 Multipurpose Fire Tender at GPU, Gandhar 8

Fig. 2.3 Foam Module Installed on Naphtha Tank-A at GAIL, Gandhar 9

LIST OF TABLES

Page
No
Table 2.1 Details of Fire Water Pumps 3

Table 2.2 Comparison of Fire Water Network with OISD-STD-116 4

Table 2.3 Comparison of First Aid Fire Protection with OISD-STD-116 5

Table 3.1 Availability of First Aid Fire Protection System in GPU, Gandhar 9

Table 3.2 Adequacy Check of First Aid Fire Protection System as per OISD-STD-116 9
 1. INTRODUCTION

1.1 ABOUT GPU, GANDHAR

GAIL (India) Limited, Gandhar plant was commissioned on 31.03.2001. It is situated at Gandhar
in the Dist. of Bharuch of Gujarat state. This is the seventh LPG Recovery plant of the parent
company GAIL (India) Ltd. The parent organization is a Maharatna PSU set up by the Govt. of
India in 1984.
GAIL Gandhar is a multi-product and service catering installation. The design capacity of the
gas processing unit at Gandhar is 5 MMSCMD (million metric standard cubic meters per day) of
natural gas. GPU feed gas is supplied from 4 sources namely:
a) Rich gas at a pressure of 30 Kg/cm2 (HP gas) from CPF, ONGCL.
b) Rich gas at a pressure of 19 to 21 Kg/ cm2, from CPF, ONGCL.
c) Rich Gas at a pressure of 27-29 Kg/ cm2 GNAQ, ONGCL.
d) Rich Gas at a pressure of 29 Kg/ cm2 from HVJ Pipeline.
Gas Processing Unit, Gandhar is designed to recover LPG (Liquefied Petroleum Gas), Pentane
and Naphtha from Natural gas produced supplied by M/S ONGC. The main consumers for these
products are state owned oil marketing companies and some private companies. The major
consumers for the lean gas (residual gas on recovery of above-mentioned products from natural
gas) include companies like RIL, GNFC, NTPC and various other small-scale industries.

1.2 STORAGE FACILITY

Following facilities exist for storage of the products:
(a) LPG - Three Mounded Storage Tanks, each having capacity of 2271 MT.
(b) Pentane - Three Bullets, each having capacity of 360 MT.
(c) Naphtha - Two external floating roof tanks, each having capacity of 762 MT.

1.3 LOADING FACILITY

Following facilities exist for loading & dispatch of the products:
(a) LPG - Road Loading Gantry with Five loading bays
(b) Pentane - Road Loading Gantry with One loading bays
(c) Naphtha - Road Loading Gantry with Two loading bay

2. REVIEW AND ADEQUACY CHECK OF WATER BASED FIRE

PROTECTION SYSTEMS OF GPU, GANDHAR
FIRE & SAFETY DEPARTMENT, GAIL GANDHAR 1
The Fire Protection systems mainly cover the plant area, off-sites, and the LPG/Naphtha/Pentane
road loading facilities. The following Fire Protection facilities are provided at GAIL, Gandhar: -
1. Fire Water Network System.
2. Automatic Fire Detection and Spray System.
3. Mobile Fire Fighting Equipments.
4. Rim Seal Fire Fighting System.

2.1 FIRE WATER NETWORK SYSTEM

2.1.1 Fire Water Flow Rate:

Firewater flow rate is based on fighting two major fires simultaneously anywhere in the
complex. Major hazardous areas have been considered for firefighting and firewater demand for
each area has been calculated. Areas which will have major firewater demands are
a) LPG unit area.
b) Pentane bullet tank farm area.
c) Naphtha tank area.
d) LPG road loading area.

2.1.2 Fire Water Pump House:

The capacity of the network has been designed considering possible occurrence of two major
fires at a time as per design philosophy of OISD-STD-116, which calculates fire water demand
of GPU, Gandhar is as 1970 m3/Hour. A reliable and adequate supply of water at minimum 10.5
Kgf/cm2 pressure for fighting fire with required flow at off-sites and plant area is assured by an
independent pressurized fire water network.
“Fire Water System” is provided with 02 open fire water tanks each having a storage capacity of
6333 m3, which conform the requirement of clause 5.4.1 of OISD-STD-116 as total fire water
storage required for GPU, Gandhar for fighting fire for minimum 04 hours is 7880 m 3. Water
supply for filling of these tanks is done by the pumps installed in the raw water reservoir. The
header from fire water tanks provides suction to 06 nos. fire water pumps and 03 nos. jockey
pumps. The delivery of these fire water pump supplies water to the entire water network. During
normal operation one of the Jockey pump will be in service to keep fire-water network under
pressure. All the pumps are provided with auto start switch. So, with the decrease in pressure in
fire water network, one after another pump starts automatically as per their logic. The details
regarding these pumps are given below:

S. No. Name Quantity Capacity Rated Head

1. Jockey Pump 03 70 m3/Hour 11 Kg/cm2

FIRE & SAFETY DEPARTMENT, GAIL GANDHAR 1

 2. Centrifugal Electric Driven Pump 02 616 m3/Hour 11 Kg/cm2

3. Centrifugal Diesel Pumps 04 616 m3/Hour 11 Kg/cm2

Table 2.1 Details of Fire Water Pumps

2.1.3 Fire Water Network:

The firewater network of GPU, Gandhar has 160 Nos. of hydrants and 103 isolation valves laid
in closed loops to ensure multi-directional flow in the system and to enabling isolation of any
section of network without affecting of flow of network. There are also 28 nos. of firewater
monitors including 04 HVLR and 02 oscillating monitors, provided at vulnerable locations. The
water monitors are given special consideration for protection of cluster of towers, heaters and
other high structures, where it may not be possible to approach the higher levels. Minimums of 2
monitors are provided for each such area. Unless otherwise decided on detailed study, monitors
and hydrants are located alternately around process units so those monitors are available for
protection of inaccessible areas and tall structures. The requirement of hydrant and monitors is
established for each process unit based on hazards involved and layout considerations. The
horizontal range and coverage of hydrants and monitors shall be as under:
Hydrant - 45 m
Monitors - 45 m
Hose reels are considered for location around unit battery limit as first aid for fire contingency.
These are floor mounted type and are having water connection from hydrant network. Each hose
reel has 1” x 30 m hose with branch pipe, which could be reached for water spray over the
affected fire area. Hose reels are located at the substation area.

Observation/Improvements/Suggestions:
 The fire water network of GPU, Gandhar is checked for closed looping to ensure multi-
directional flow and isolation valves in network as well as on each hydrant to enabling
isolation of required section of network, all are found as per statutory requirement.
 The firewater mains have not been properly supported on sleepers at western side of unit
area of plant, as per clause 5.6.2 OISD-STD-116 the fire water network shall be supported
by sleepers at regular interval not exceeding 6 meters.

 The inter distance of fire hydrants of GPU, Gandhar also measured and compared with
minimum statutory requirement conforming to clause 5.7.1 of OISD-STD-116. The findings
are as below table:

Table 2.2 Comparison of Fire Water Network Installation with OISD-STD-116

FIRE & SAFETY DEPARTMENT, GAIL GANDHAR 1

 S. No of Hydrants and Monitors Remarks (if,
Location
No. Required Available at site Any)

1. Admin Building and

Hydrants: 5 Monitors: 0 Hydrants: 6 Monitors: 0
Canteen
2. Mechanical Workshop,
Hydrants: 7 Monitors: 0 Hydrants: 7 Monitors: 0
O&M Store
3. Fire Station Hydrants: 3 Monitors: 0 Hydrants: 3 Monitors: 0
4. FWPH Hydrants: 2 Monitors: 0 Hydrants: 2 Monitors: 0

5. Chemical Dosing Area,

Hydrants: 8 Monitors: 0 Hydrants: 8 Monitors: 0
Diesel Storage
6. 66 KVA Switchyard Hydrants: 8 Monitors: 0 Hydrants:12 Monitors: 0
7. Lab Hydrants: 3 Monitors: 0 Hydrants: 5 Monitors: 0
8. Cooling Tower Hydrants: 5 Monitors: 0 Hydrants: 8 Monitors: 0
9. PSA N2 Plant Hydrants: 4 Monitors: 0 Hydrants: 6 Monitors: 0
10. Boiler Hydrants: 4 Monitors: 1 Hydrants: 4 Monitors: 1
11. Substation – 1 Hydrants:12 Monitors: 0 Hydrants:12 Monitors: 0
12. MCR Hydrants:6 Monitors: 0 Hydrants:8 Monitors: 0
13. Future Expansion Area Hydrants:8 Monitors:0 Hydrants:10 Monitors:0
14. GMS Area Hydrants:10 Monitors:4 Hydrants:10 Monitors:4
15. Unit Area Hydrants:15 Monitors:8 Hydrants:16 Monitors:8
16. Substation – 2 & 3 Hydrants:4 Monitors: 0 Hydrants:5 Monitors: 0
17. LPG Mounded Bullet Hydrants:15 Monitors:3 Hydrants:15 Monitors:3
18. Pentane Bullet Hydrants:6 Monitors:2 Hydrants:6 Monitors:2
19. Naphtha Storage Hydrants:5 Monitors:2 Hydrants:5 Monitors:2

20. Mercaptan & Methanol

Hydrants:5 Monitors:0 Hydrants:5 Monitors:0
Storage
21. LPG & Pentane Gantry Hydrants:11 Monitors:6 Hydrants:11 Monitors:6
22. Weigh Bridge Hydrants:3 Monitors: 0 Hydrants:3 Monitors: 0

FIRE & SAFETY DEPARTMENT, GAIL GANDHAR 1

 23. Loading & Automation
Hydrants:3 Monitors: 0 Hydrants:3 Monitors: 0
Control Room
24. WWTP Hydrants:15 Monitors: 0 Hydrants:15 Monitors: 0
25. Flare Area Hydrants:4 Monitors: 1 Hydrants:4 Monitors: 1
26. Fire Training Ground Hydrants:5 Monitors: 1 Hydrants:5 Monitors: 1
27. Old C&P Store Hydrants:3 Monitors: 0 Hydrants:3 Monitors: 1
28. CISF Barrack Hydrants:3 Monitors: 0 Hydrants:3 Monitors: 0
29. Microwave Station Hydrants:2 Monitors: 0 Hydrants:2 Monitors: 0

Fig. 2.1 Fire Water Network and Protection system Layout of GPU, Gandhar

2.2 FIXED WATER SPRAY SYSTEM

Fixed water spray system with medium velocity designed as per requirement of OISD-STD-116
has been provided at various facilities like mounded bullet (dome, tunnel & pump house),
loading gantry for LPG, Naphtha & Pentane, loading pumps, flare knock out drums, Driers,

FIRE & SAFETY DEPARTMENT, GAIL GANDHAR 1

pumps in unit area, pentane bullets & Naphtha storage tanks for effective cooling of exposed
facilities in case of any fire/UVCE/BLEVE.
Water spray system of Mounded bullet area (Dome & LPG pump shed) can be operated
automatically, remotely or locally from Main control room & from deluge valve itself.
Automatic water spray of mounded bullet area starts when quartzoid bulb provided on the airline
breaks at a temperature 79 °C and hence instrument air supplied to quartzoid bulb starts leaking.
When the pressure reaches the set point of pressure switch, it activates the followings.
i) Water spray system.
ii) Trips loading pumps to stop loading.

Water spray system on LPG & NAPHTHA+PENTANE loading gantry can be started remotely
from main control room in case of gas leakage or fire. The above-mentioned deluge valve meant
for loading gantry can also be operated by opening the bypass valve provided on the south side
of the loading gantry.

Observation/Improvements/Suggestions:

GPU, Gandhar has fixed water spray system for Naphtha gantries, which has limited application
of cooling of takers only if exposed to heat in case of fire. The fixed water spray system could
have adverse effect for liquid hydrocarbon (Naphtha) fires as application of water spray may
reduce the aqueous film formation, and fire extinguishing ability of firefighting foam. Moreover,
water spray could spread the fire by means of spreading fuel.

2.3 MOBILE FIRE FIGHTING EQUIPMENTS

Two number of water/foam/DCP fire tenders have been provided at GPU Gandhar for attending
any emergency call immediately at the incipient stage. The fire station is manned round the clock
with trained Fire Personnel. The Fire Tenders have the following facilities:
1. Water Tank capacity: 4500/4000 liters
2. Foam Tank capacity: 1000/240 liters
3. Pump discharge capacity: 2250 LPM @ 8.5 Kg/cm2
4. DCP vessel capacity: 2000/1000 Kgs.
5. Monitor discharge capacity: 1800 LPM with 45 m throw.

FIRE & SAFETY DEPARTMENT, GAIL GANDHAR 1

 Fig. 2.2 Multipurpose Fire Tender at GPU, Gandhar

2.4 FOAM BASED FIRE PROTECTION FOR FLOATING ROOF TANK

2.4.1 Rim Seal Fire Protection System:

The automatic rim seal fire detection & extinguishing system is provided to detect and extinguish
the rim seal fire over external floating roof tanks storing Naphtha at the incipient stage. The
automatic rim seal fire detection & extinguishing system immediately detects & suppresses a rim
seal fire till such time the semi fixed foam system is activated. The extinguishing system is
designed to be a primary device, which deploys 3% low expansion foam onto the fire within the
first few seconds of it being detected. The aim being to contain and extinguish a fire before it
develops into a fully evolved fire.
The system consists of one number of standalone foam discharging unit (Foam Modules). Each
foam discharging units complete with their deployment facilities consists of auto actuation foam
discharge valve, solenoid valve, manual isolation ball valve, pressure switch, pressure gauge and
safety valve etc. To facilitate periodic testing a test nozzle per each module is also provided to
operate the system without discharging the foam solution into rim seal gap /area.
Foam extinguishing system consists of: -
a) Pre-mixed 3% AFFF 5 Liters only and 145 Liters water.
b) Foam discharge manifold with nozzles.
c) Auto actuation foam discharge valve and manual isolation valve.
d) Level switch to monitor the foam solution level inside the module.
e) Safety valve for over pressure relief.
f) Pressure Gauge to indicate the pressure inside the module.
g) Instrument Panel Board Containing Nitrogen – Charging manifold, pressure switch to
monitor the foam module pressure & solenoid valve to activate the foam discharge valve.
h) Module pre-fabricated mounting frame & Canopy for the protection of module.

FIRE & SAFETY DEPARTMENT, GAIL GANDHAR 1

 Fig. 2.3 Foam Module Installed on Naphtha Tank-A at GPU, Gandhar

2.4.2 Semi-Fixed Foam System:

Semi-fixed foam system is provided for the protection of both the Naphtha tanks A and B. Foam
Maker is installed at the top of each tank wall with system pipe extended up to roadside at safe
distance from tank. When required the system to be charged with foam solution (Water from
hydrant and foam concentration to be inducted from foam trolley with the help of inline
inductor). Orifice plate is provided at inlet of foam maker to control flow rate. Foam solution
gets aerated at foam maker and after sufficient expansion gets into the tank from foam pourers.

3. REVIEW AND ADEQUACY CHECK OF FIRST AID FIRE

PROTECTION SYSTEMS OF GPU, GANDHAR

3.1 First Aid Fire Fighting Equipment

Fire should be killed or extinguished at the incipient stage before it can cause any major damage to
the human as well as critical Equipments in the plant. The gas procession plants carry inherent hazard
and fire at any area may endanger other parts of the plant also. So, it has to be controlled as soon as
possible. For this purpose, portable fire extinguishers of different type are provided at all strategic
location inside the plant areas. The different types of extinguishers provided are: -

i) Dry Chemical Powder Extinguishers (1, 5, 9, 10, 50 & 75 Kg type)

ii) CO2 Extinguishers (4.5, 6.8 Kg).

Depending upon the type of fire, suitable fire extinguisher will be used for firefighting in the initial
stage by the operating persons trained for operation of Fire Extinguisher.

FIRE & SAFETY DEPARTMENT, GAIL GANDHAR 1

 Type of Extinguisher Quantity Remarks (if,
DCP (Kgs) Total Working Any)
75 10 10
50 20 20
10 102 102
9 100 100
Table 3.1 Availability of First Aid Fire Protection50System in GPU, Gandhar
6 50
5 32 32
1 20 20
S. CO2 (Kgs) No of Extinguishers Remarks (Current
No. 4.5 94 94 Status, If sufficient
Location
6.8 25
Required 25 Available Extinguishers
Provided (YES/NO))
1. Admin Building 21 19 YES
2. Canteen 2 3 YES
3. Mechanical Workshop 7 8 YES
4. O&M Store 3 3 YES
5. Fire Station 2 0 YES
6. FWPH 2 4 YES

7. Chemical Dosing Area 2 4 YES

8. Diesel Storage 3 2 YES

9. 66 KVA Switchyard 14 16 YES

10. Lab 3 5 YES

11. Cooling Tower 2 2 YES

12. Acid Storage 1 1 YES

13. PSA N2 Plant 2 5 YES

14. Boiler 2 3 YES

15. Substation – 1 24 24 YES

16. MCR 7 17 YES

17. GMS Area 34 39 YES

FIRE & SAFETY DEPARTMENT, GAIL GANDHAR 1

18. Unit Area 58 58 YES

19. Substation – 2 2 4 YES

20. Substation – 3 2 5 YES

21. LPG Mounded Bullet 2 2 YES

22. Pentane Bullet 2 3 YES

23. Naphtha Storage 3 4 YES

24. Mercaptan 1 2 YES

25. Methanol Storage 1 1 YES

26. LPG 14 15 YES

27. Pentane Gantry 8 12 YES

28. Weigh Bridge 1 3 YES

29. Loading & Automation YES

3 4
Control Room
30. WWTP 7 10 YES

31. Flare Area 3 3 YES

32. CISF Barrack 2 2 YES

33. Microwave Station 1 1 YES

34. Main Gate 1 1 YES

35. Material Gate 1 1 YES

36. Raw Water Reservoir 2 2 YES

Table 3.2 Adequacy Check of First Aid Fire Protection System as per OISD-STD-116

REFERENCES

FIRE & SAFETY DEPARTMENT, GAIL GANDHAR 1

  OISD-STD-116 Fire Protection Facilities for Petroleum Refineries and Oil Gas
Processing Plants.
 Indian Standard 2190:2010 Selection, Installation and Maintenance of First-Aid Fire
Extinguishers -code of practice
 Onsite Emergency Action Plan of GPU, Gandhar.
 Emergency Response and Disaster Management Plan of GPU, Gandhar.
 Gandharnet.

APPENDIX-A

FIRE & SAFETY DEPARTMENT, GAIL GANDHAR 1

 APPENDIX-B

FIRE & SAFETY DEPARTMENT, GAIL GANDHAR 1