KARBALA REFINERY PROJECT

UTILITY PROCESS TRAINING -BASIC

(COURSE CODE : ETI-PR-02B)

By Mahendrakumar Patel

UNIT 31 – Fire Water Unit

CONTENT Page : 2 / 19
S
1. INTRODUCTION
1) Introduction of Training Course Contents
2) Introduction of Training Schedule

2. PROCESS OVERVIEW
1) Purpose
2) Basis of Design
3) Process Description

3. PROCESS FLOW AND CONTROL

1) Process Variables
2) Major Equipment
3) Complex Control Logic

4. START-UP AND SHUTDOWN

1) Startup Sequence
2) Shutdown Sequence
Course Content and Duration ( One Day Session) :
First Day 08/03/2021:

 U-31 Fire Content Time :

water

1 INTRODUCTION
1. Introduction of Training Course Contents 09.00 to 09.20
2. Introduction of Training Schedule
2 PROCESS OVERVIEW
2. Process Principle 09.20 to 09.35
3. Basis of Design
3 PROCESS FLOW AND CONTROL
1) Process Variables 10.00 to 10.45
2) Major Equipment
3) Complex Control Logic
4 START-UP AND SHUTDOWN

1. Startup Sequence 11.00 to 11.30

2. Shutdown Sequence
3. Evaluation Test March End
2. PROCESS Page : 4 / 19
OVERVIEW

 Purpose :

 The system provides the supply of refinery fire water to refinery area.

 Firewater refers to water that has been used in firefighting and it

requires disposal.
 In many cases, it is a highly polluting material and requires special
care in its disposal
 Basis of Design : (Storage Capacity ) :
– Capacity
 System Capacity : 8,857 m3 (One Storage Tank, 6.5 hours hold-up)

 Four Firewater Main Pumps: 681.3 m3/hr with 10.5 kg/cm2g each

 Two Electric Motor Driven Pumps + Two Diesel Engine Driven Pumps
Worst Fire Scenarios :

Firewater
FIRE ZONE Fire Fighting Facilities Applied Demand
(m3/hr)

Vacuum Gasoil HDT Unit Water Spray / Firewater 1,221.8

(U07) Monitor / Hose Stream

Fluid Catalytic Cracking Water Spray / Firewater 1,293.6

Unit (U08) Monitor / Hose Stream

Tank Farm Unit (U52) Water Spray / Foam Injection System 1,142.2

Depot Area (U90) Water Spray / Foam Injection System 1,101.4

8. Fire Fighting System

Jockey Pump

Diesel Engine Driven Fire Pump

8. Fire Fighting System
Fire Fighting Tools

Hydrant Spraying Nozzle

Conventional Hydrant Monitor

Fire Fighting Tools and Hose Reel Portable Foam Feeder Portable Hydrant Spray Nozzle
9. Fire Fighting System

Deluge SystemDeluge
system worrk_360p.mp4

Inergen SystemInergen Gas Detectors

Fire Suppression Systems_480p.mp4
Foam Injection System for Tanks
2. PROCESS OVERVIEW (Continued) Page : 5 / 19

Simplified PFD

Filtered
Water

Fire Water
To
Network
AG UG

FWP ED FWP D/D JOCKEY PUMP

2. PROCESS OVERVIEW (Continued) Page : 6 / 19

- Overall Plot plan

3A AREA
UNIT 31
2. PROCESS OVERVIEW (Continued) Page : 7 / 19

- Area Plot plan (3A)

UNIT 31
2. PROCESS OVERVIEW (Continued) Page : 8 / 19

- Plot plan
2. PROCESS OVERVIEW (Continued) Page : 9 / 19

- 3D Model
2. PROCESS OVERVIEW (Continued) Page : 10 / 19

- Process Description

Fire Water Unit

Fire water unit serves to supply fire water to refinery area through the underground fire
water network. \
 Its aim is to supply fire water in case of fire took place through dedicated fire
protection equipment such as water spray, monitors and foam system.
The unit is designed to fully cover the fire water demand of single worst fire scenario
that can be happened in refinery area with certain required time.
Filtered water is the source of fire water and it is from Raw Water Treatment Unit
(U30) and pressurize the fire water network to 10.5kg/cm2g through Jockey Pumps (31-P-
002A/B).
When fire water from dedicated equipment are in use, the pressure of the firewater
network will be decreased causing the main firewater pumps to run.

All firewater pumps has its own pressure sensing instruments to run the pump, when the set pressures are

reached.

The set pressure and the operating sequence are as per below;
3. PROCESS FLOW AND Page : 11 / 19
CONTROL
- Process Variable

The most important and critical variables for the Fire Water Unit are:
 Liquid level of Firewater Tank (31-TK-001)

The correct fire water level inside the firewater tank is essential:

 to prevent lack of fire water supply in case of fire emergencies.

 to avoid damage to the fire water pumps when in use.

 Firewater Tank level (31-LI-0001A) working range is 17 % (Low) to 81 % (High)

 Liquid level of Firewater Piping Boot (31-V-001)

The correct fire water level inside the firewater tank is essential:

 Time shall be secured to open the PIV which isolates the firewater network of Refiner and
Depot area.

 Firewater Piping Boot level (31-LI-0002) working range is 13 % (Low) to 93 % (High)

3. PROCESS FLOW AND CONTROL (Continued) Page : 12 / 19

- Major Equipment

Fire Water Tank (31-TK-001)

 Firewater make-up is taken from Filtered Water Storage Tanks (30-TK-001A/B) by Filtered Water
Pumps (30-P-002A/B/C).

 Working volume is 8,857 m3, which is based on 6.5 hour supply under firewater pumps rated
capacity of 1,362.6 m3/h.

 Tank is fixed roof atmospheric type. They are commonly used to store large
(

quantities of petroleum distillates, petrochemicals, and other liquid chemicals at

atmospheric pressure.

Fire Water Piping Boot (31-V-001)

 Item dedicated to allow the time delivering firewater from Depot area.

 Working volume is 113.6 m3, which is based on 5 minutes supply under firewater pumps rated
capacity of 1,362.6m3/h.

 Since the lead jockey pumps(31-P-002A) circulates to the fire water tank only, piping boot is
traced for winterization.
3. PROCESS FLOW AND CONTROL (Continued) Page : 13 / 19

- Major Equipment :
 Fire Water Pump (31-P-001A/B/C/D)

 Four pumps (two first duty and two stand-by) with 2 X 50% (681.3 m3/h) rated
capacity are provided.

 Maximum firewater demand is 1293.6 m3/h as mentioned in the design basis,

two firewater pumps cover the demand.

 31-P-001A/B are electric motor driven / 31-P-001C/D are diesel engine driven.

 Jockey Pump (31-P-002A/B)

 Two pumps (one lead and one lag) with 60m3/h rated capacity each.

 Acts as main pressurizer of the firewater network and provides capacity for
small firewater draw-offs such as fire hoses.

 Lead jockey pump (31-P-002A) remains in operation all the time circulating
through spillback line to firewater tank.
4. START- UP AND Page : 14 / 19
SHUTDOWN
- Start-up Procedure
4. START- UP AND SHUTDOWN (Continuted) Page : 15 / 19

1. Fill the Firewater tank (31-TK-001) / Piping Boot (31-V-001)

 Check the tanks line-up is ready to receive water.
 Ensure all block valves are opened.

 Ensure the block valves to pump suction lines are in closed position.

 Set 31-LIC-0001A / 31-LIC-0002 output is 0.0% in manual mode.

 Make sure raw water treatment unit (Unit 30) in operation.

 Ensure control valves (31-LV-0001A / 31-LV-0002) are in service. (Bypass Closed)

 Input the target level in 31-LIC-0001A / 31-LIC-0002 in manual.

 Adjust manual output of 31-LIC-0001A / 31-LIC-0002 to 1.0%.

 Water level will be increased to 1.0%, checked through 31-LI-0001A / 31-LI-0002.

 When water level reaches 1.0%, change the mode of 31-LIC-0001A / 31-LIC-0002 to Auto.
4. START- UP AND SHUTDOWN (Continuted) Page : 16 / 19

2. Start firewater pump :

 Make sure level of tank 31-TK-001 is higher than 20% of the level indicator with

Auto mode, since the underground firewater network shall be filled.

 Open suction and discharge valves of 31-P-001A/B/C/D, 31-P-002A/B and remove

remaining air by opening vent valves.

 At the end of water filling, water make-up valves (31-LV-0001A) will be almost
closed.

 Follow the normal start-up procedure.

 Start 31-P-001A.
 Check the pump conditions such as vibrations and noises.
 Adjust the opening of discharge block valve to achieve discharge pressure (31-PG-0001A)
and then open fully.
 When firewater network pressure reaches 10.5kg/cm2g through 31-PI-0001,
stop the firewater pump (31-P-001A) and start the lead jockey pump(31-P-002A) to maintain
the network pressure.

 Switch the operation of firewater pumps (31-P-001A/B/C/D) and jockey pumps (31-P-002A/B)
into Auto mode.
4. START- UP AND SHUTDOWN (Continuted) Page : 17 / 19

3. Biocide Injection :

 For initial start-up, about 14kg of Biocide shall be dosed into the system.

 Target concentration for residual chlorine is 0.2wt ppm. Check it periodically

at sample point 31-SC-001 and if it lacks, additional biocide shall be

injected.
1) Open valves 1, 2, 3 and pour in about 2L at a time and close valve 1.

2) Slowly open valve 4 and inject the Biocide. 1~2minutes later, close valve 2,3,4 and drain the remaining through valve 5.

3) After checking the pressure inside dosing pot by 31-PG-0005, close valve 5 and repeat the process again to meet the

target quantity.
4. START- UP AND SHUTDOWN (Continuted) Page : 18 / 19

4.
Firewater Piping Boot Operation :
 In case of abnormal conditions such as firewater tank water
level low or failure,
 Firewater system from Depot area shall be shared with
refinery area.
 To ensure the time required to open the isolation valves
between two firewater network, ……….firewater piping
boot shall be operated.

1)Ensure the firewater level inside the firewater piping boot is

maintained at HHLL at all times.

2)Firewater tank level low is detected (31-LIC-0001A/B),

firewater piping boot bottom locked closed valve shall be
opened.
3)While the firewater is supplied from the fire water piping
boot, PIVs which isolates the Refinery area and Depot area
shall be turned open (90-PIV-005 / 90-PIV-025).
4. START- UP AND SHUTDOWN (Continuted) Page : 19 / 19

 Shutdown Procedure :
 Firewater operation must be maintained to secure refinery anytime since flammable
materials are handled,
 Firewater system shall not be shutdown.
 Thus manual shutdown is not applied to firewater system.

 Partial Shutdown

Although the fire water system is for intermittent use, there are very low possibilities for the
maintenance of firewater pumps.

Partial maintenance shutdown of firewater pumps shall be done considering below;

1) Worst Condition ….maximum firewater demand……., firewater pump shall be

maintained one at a time.

2) Regardless of the maintenance, all other firewater pumps shall be ready for operation at
all times.

3) Firewater pumps maintenance of unit 31 and 90 shall not be conducted at the same time.

4) At firewater pump maintenance, operator shall be ready for the Firewater piping boot
operation in case of emergencies.
Thanks Any Question
Jockey Pump

On a fire protection system requiring a fire pump, there is a small

pump that maintains pressure above the pressure settings of the
larger fire pump. Hence the name "jockey pump.“

The purpose of a jockey pump is to maintain pressure in a fire

protection piping system so the larger fire pump does not need
to run. A jockey pump package consists of a pump, motor and
controller.