BULK STORAGE FACILITY

Safety Design Philosophy

CQS-EPR-TS-GEN-PHL-002

27-06-16 3.0 Issued for Approval C.M.O A.E.O O.A.F

06-06-16 2.0 Issued for Review C.M.O A.E.O O.A.F

24-05-16 1.0 Issued for Interdiscipline Check C.M.O A.E.O O.A.F

PM
Date Rev Description Prepared by Reviewed by
Approval
Bulk Storage Facility CQS-EPR-TS-GEN-PHL-002
Safety Design Philosophy Rev 3.0

TABLE OF CONTENTS

1.0 INTRODUCTION .................................................................................................. 3

1.1 SCOPE ................................................................................................................. 3
1.2 Definitions ............................................................................................................. 3
1.3 Codes and Standards ........................................................................................... 3
1.4 Abbreviations ........................................................................................................ 4
1.5 Objectives ............................................................................................................. 4
2.0 FACILITY SURVEY / HAZARD ASSESSMENT .................................................. 5
2.1 Hazard identification ............................................................................................. 5
2.2 Facility survey ....................................................................................................... 5
2.2.1Storage tank contents hazard assessment ........................................................... 5
2.2.2Loading area......................................................................................................... 5
2.2.3Administrative / Utility building .............................................................................. 5
3.0 HAZARD PREVENTION ...................................................................................... 6
3.1 Tank location and proper arrangement ................................................................. 6
3.2 Close circuit television (CCTV) ............................................................................. 6
4.0 MEASURES OF MITIGATING ESCALATION RISK ........................................... 7
4.1 Passive fire protection (PFP) ................................................................................ 7
4.1.1Emergency response ............................................................................................ 7
4.1.2Evacuation, escape and rescue............................................................................ 7
4.1.3Flame detection .................................................................................................... 8
4.1.4Manual Call Point ................................................................................................. 8
4.1.5Communication system ........................................................................................ 8
4.1.6Bund walls ............................................................................................................ 8
4.2 Active fire protection (AFP) ................................................................................... 8
4.2.1Storage Tank area ................................................................................................ 9
4.2.2Loading area....................................................................................................... 10
4.2.3Administrative / utility building............................................................................. 11
5.0 FIRE SUPPRESSION CAPABILITY .................................................................. 12
6.0 SAFETY DESIGN DEVELOPMENT .................................................................. 13

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1.0 INTRODUCTION
Eko Petrochem and Refining Company Limited wishes to construct and commission
20 new PMS storage tanks on a green field maximizing its capacity utilization.

In view of this, Crystaquantum Solutions has been awarded the contract to carry out
the Detailed Engineering Design and the requisite design to meet industry and
regulatory requirements.

The facility is intended to hold storage of one white product, Premium Motor Spirit
(PMS). The tank farm has a combined storage capacity of 453,640 cubic metres of
PMS.

1.1 SCOPE
This Safety Philosophy is to address the approach to the protection for Eko Petrochem
and Refining Company Limited BULK STORAGE FACILITY PROJECT, with respect
to safety of personnel, conservation of the environment and work area.

The following areas are covered in the Safety Design Philosophy

 Facility survey to assess factors related to potential hazards

 Review of potential incident types / Hazard Assessment
 Hazard Prevention
 Safety Systems and Mitigations measures

1.2 Definitions
SHALL: To be understood as mandatory. Deviating from a “shall” statement
requires derogation approved by the COMPANY.

COMPANY: means Eko Petrochem and Refining Company Limited

SHOULD: To be understood as recommended to comply with.

MAY: To be use where alternatives are equally acceptable.

1.3 Codes and Standards

This report shall conform to the latest issue of the relevant codes and standards from
the following organizations:

 API RECOMMENDED PRACTICE 2021, Management of Atmospheric Storage

Tank Fires.
 NFPA 11, Standard for Low-, Medium- and High-Expansion Foam
2005

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 IP-Model Code P19, Fire Precautions At Petroleum Refineries and Bulk

Storage Installations
1.4 Abbreviations
AFFF: Aqueous Film Forming Foam

API: American Petroleum Institute

FEED: Front End Engineering Design

IP: Institute of Petroleum

NFPA: National Fire Protection Association

PMS: Premium Motor Spirit

1.5 Objectives
This philosophy is aimed at higlighting:

 Specific safety requirements as regard the design of Eko Petrochem and

Refining Company Limited BULK STORAGE FACILITY PROJECT Measures
to avoid exposure to potential hazards.
 The preventive measures put in place to eliminate/reduce the occurrence of
hazards in other to provide a safe working environment for site personnel.
 The diverse control and mitigation adopted on the facility to ensure that the
integrity of the entire system is not jeopardised by the design and installation
system.
 Escape and evacuation means provided to safeguard personnel during
emergencies.

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2.0 FACILITY SURVEY / HAZARD ASSESSMENT

2.1 Hazard identification
The major Hazards identified from the study for specific hazards related to the
construction and operation of Eko Petrochem and Refining Company Limited BULK
STORAGE FACILITY PROJECT can be categorized into

 Fire and Explosion

 Risk to personnel safety
 Environmental issues
 Structural failure

2.2 Facility survey

An initial Survey of various sections of the facility was done to assess factors related
to fire potential and to identify the types of hazard that could occur at the facility.

2.2.1 Storage tank contents hazard assessment

The characteristics of a tank’s contents directly affect the potential for a fire in that
tank. The initial survey of the tank farm showed the type of liquid contained in the
atmospheric tanks; flammable or combustible liquid, tank contents, tank sizes, roof
types and potential fire hazards.

TANK INVENTORY
TANK ROOF POTENTIAL FIRE
SIZE INVENTORY PROPERTIES/ DESIGN HAZARD
TAG
D X H (m) FLASH POINT

Dome Vent Fire, Obstructed

ABJ- Flammable roof with rim seal fire,
0101- 38 X 20 PMS internal Obstructed Full Liquid
0120 <-40oC (-40oF) floating Surface Fire, Overfill /
blanket leakage ground fire
Dome Vent Fire, Obstructed
ABJ- roof with rim seal fire,
Flammable <-
0301- 10 X 8 PMS Slop internal Obstructed Full Liquid
40oC (-40oF)
0305 floating Surface Fire, Overfill /
blanket leakage ground fire

2.2.2 Loading area

POTENTIAL FIRE HAZARD: Vent fire and Jet fire

2.2.3 Administrative / Utility building

POTENTIAL FIRE HAZARD: Class A and C Fire.

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3.0 HAZARD PREVENTION

To ensure that safety of the overall facility is maintained at the highest level, the
occurrence of hazards shall be prevented as much as possible. This entails proper
layout of the equipments and storage tanks and strict adherence to operating manual
during start-up and operation of the system.

3.1 Tank location and proper arrangement

The location of storage tanks is significant in several respects. Proximity to ignition
sources influences probability for ignition if there is a release of material from storage.

Distance to fence lines is significant in respect to potential impact of a tank fire incident
if there are relevant exposures of concern; proximity to the fence line also increases
the potential for mischief originating from off-site.

In case of a fire, the distance to firewater supplies will affect flow and pressure.

Equipment arrangement within the Eko Petrochem and Refining Company Limited
BULK STORAGE FACILITY PROJECT shall be done in conformity with NFPA 30
such that process safety and personnel safety are maintained. It shall also allow for
easy operation of the facility.

3.2 Close circuit television (CCTV)

CCTV shall be located at the gate and strategic positions around the fence line for
intruders, at the gantry area for surveillance / detections, tank area for detecting
flames / release of gas, pump station and instrumentation control room for operations
monitoring.

The two main objectives are:

 To have complete records of incidents in a predefined area.

 Continuous/full operation of the tank farm systems to avoid intrusion.

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4.0 MEASURES OF MITIGATING ESCALATION RISK

The measures of mitigating escalation risk involve passive and active means. In the
content of this project the failure or absence of these may lead to serious escalation
of an initial fire/explosion hazard.

4.1 Passive fire protection (PFP)

PFP provides safety to life and mitigation of fire escalation by containing a fire in the
fire compartment of origin, thus limiting the spread of fire and smoke for a limited period
of time.

The PFP recommended for Eko Petrochem and Refining Company Limited BULK
STORAGE FACILITY PROJECT includes but not limited to:

 Bund walls and separation/segregation walls

 Non-combustible thermal insulation of tanks
 Fire proofing of structural steel
 Flame shields and insulation of electrical or instrument cable systems
 Alarms and detection systems
 External layers of insulating materials on pipe works
 Escape, Evacuation and rescue facility
 Emergency Shutdown (ESD)
 Instrumentation to control spillage and protection against overfill

4.1.1 Emergency response

Provisions shall be made for the emergency response equipment in the event that an
accident occurs even after preventive and protective measures have been put in place.
Evacuation and rescue means of personnel from accident location to a safe place shall
be provided.

4.1.2 Evacuation, escape and rescue

Escape routes shall be marked to show way of escape to the muster point area, then
out of the facility if the hazard is out of control within a given specified period/time.

The muster point shall be located in a place assessible from any area in the facility
with no obstruction.

Incase of explosion or serious fire, personnel at the tank area, who can not get to the
muster point should leave the facility through the emergency exit only.

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4.1.3 Flame detection

The flame detection associated with the Eko Petrochem and Refining Company
Limited BULK STORAGE FACILITY PROJECT shall:

 Provide audible and visual indication of fuel fire at long distances both locally
and in the control room.
 Where installed, initiate the isolation and depressurization of flammable
inventories in the event of fire.
 Located at strategic positions such as the storage area and loading gantry.

4.1.4 Manual Call Point

Manual call points shall be strategically distributed near access/exits so they may be
quickly accessed. They shall be of pull-action type.

4.1.5 Communication system

Audible and visual alarm(s) shall be provided (where necessary) to notify personnel of
a potential risk/occurrence of an accident. This alarm shall be heard and see on every
part of the facility.

Automatic and manual activation means shall be made available to initiate the fire
alarms and Emergency shutdown (ESD) from the fire system while the evacuation
alarm shall be initiated manually.

4.1.6 Bund walls

The bund wall/area seperation should be provided around the tanks, this will help to
protect fire from spreading to other tank area, (prevent escalation of fire to other tanks
and facilities around the tank farm) and contain spills in case of spillage. It is very
important to always keep the tank farm area very neat to avoid the easy escalation of
ground fire especially at the bund wall arena.

4.2 Active fire protection (AFP)

Basically, three fire protection / suppression strategies exist: abandonment, defensive
and offensive. Either of them may be applied to obtain the objective of this section.
The type of fire hazard and fire suppression capability will help determine the best
strategy to be used.

The offensive strategy is an aggressive attack to attempt to extinguish the tank fire. It
is the first option considered whenever adequate resources are present and there is a
reasonable chance of successful fire extinguishment. It is typically employed during

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vent fires, ground fires, rim seal fires, and unobstructed full liquid surface fires in small
to medium size tanks.

The defensive strategy protects the personnel and exposed equipment and allows the
fire to burn out without spreading to other equipment. It should be considered when
tank conditions (such as a sunken roof obstructing large portions of the fuel surface,
large diameter obstructed full liquid surface fires with no boilover potential) or lacks of
resources preclude a successful offensive strategy.

The abandonment (or evacuation) strategy involves no fire fighting activities; the fire
will be allowed to burn out and the area evacuated if necessary for personnel safety.
It should be considered when there is shortage of fire fighting personnel and materials
(foam and water), imminent danger of a boil over, tank failure, or other life-threatening
occurrence, requiring immediate evacuation of the area.

4.2.1 Storage Tank area

STRATEGY TO FIGHT FIRE
Extinguishment:
 Hydrants and Hose Boxes: Each fire main should be provided with a suitable
number of hydrants spaced at appropriate distances (50m-100m) giving a
maximum Hose length from Hydrant to nozzle of 30m – 50m to give adequate
covers to the appropriate area. Siting of the hydrants should facilitate tackling
fires or giving protection in adjacent areas. They may be used to supply water
which serves as a cooling, quenching, smothering, diluting, and displacing
agent.

 Fixed Monitor: Fixed monitors should be used to apply water, foam or dual
agents. They are placed at appropriate area to fight fire or cool the tanks. A
Fixed Monitor may be desirably use at spot location because their area of
coverage is limited. It should be properly and carefully placed to provide
optimum coverage.

 Foam Pourer: This is a foam discharge outlet attached to the periphery of a

tank shell to introduce foam. Foam is a stable aggregate of small bubbles of air
in a water-based foam solution resulting in a lower density than either oil or
water. It flows over a liquid surface and forms an air-excluding, continuous
blanket that inhibits the release of flammable vapors. The number of foam
pourer is dependent on the diameter of the tank (NFPA 11, pg 14). For this
storage depot, each tank shall have a minimum of two foam pourers.

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 Fire Extinguishers: Dry Chemical and AFFF should be used to suppress or

extinguish the Fire. They should be installed in an accessible spot and
positioned in a way that the instructions on the extinguisher face outward.

Exposure protection:
 Cooling Water: Water shall be used to cool equipment, structures, and tank
shells that are exposed to the heat from a fire, thus preventing or reducing both
heat damage to equipment and overpressure that could result from overheating
vessel contents.

Detection and Prevention System:

 Detection system (IR3 Flame Detector)
 Ignition Prevention system (Thunder Arrestor).
They should be installed in strategic positions to minimize loss of lives or serious injury,
prevent the spread of fire or extinguish it in the early stage.

4.2.2 Loading area

STRATEGY TO FIGHT FIRE
Extinguishment:
 Fixed Monitor: Fixed monitors should be used to apply water, foam or dual
agents. They are placed at appropriate area to fight fire. A Fixed Monitor may
be desirably use at spot location because their area of coverage is limited. It
should be properly and carefully placed to provide optimum coverage.

 Sprinklers: They shall be installed at the loading bay to suppress fire or cool
adjacent areas.

 Fire Extinguishers: Dry Chemical and AFFF should be used to suppress or

extinguish the Fire. They should be installed in an accessible spot and
positioned in a way that the instructions on the extinguisher face outward.

 Hydrants and Hose Boxes: Each fire main should be provided with a suitable
number of hydrants spaced at appropriate distances (50m-100m) giving a
maximum Hose length from Hydrant to nozzle of 30m – 50m to give adequate
covers to the appropriate area. Sitting of the hydrants should facilitate tackling
fires or giving protection in adjacent areas.

Detection and Prevention System:

 Detection system (IR3 Flame Detector):They should be installed in strategic
positions to minimize loss of lives or serious injury, prevent the spread of fire
or extinguish it in the early stage.

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4.2.3 Administrative / utility building

STRATEGY TO FIGHT FIRE
Extinguishing:
 Fire Extinguishers: Dry Chemical, CO2 or wet chemical fire extinguisher
(dependent on the type of fire) should be used to suppress or extinguish the
Fire. They should be installed in an accessible spot free from blocking by
storage and equipment and near room that provides an escape route. It should
be positioned in a way that the instructions on the extinguisher face outward.

Detection and Prevention System:

 Detection system (smoke);They should be installed in the building to
minimize loss of lives or serious injury, prevent the spread of fire or extinguish
it in the early stage.

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5.0 FIRE SUPPRESSION CAPABILITY

The capability for suppressing a fire relates to understanding the resources required
and then being able to apply them to problem resolution. The basic fire-suppression
resource needed for most non-pressurized hydrocarbon fires is firefighting foam. This
in turn requires water, foam concentrate and the means of delivering an expanded
foam solution to the right location, in the right quantity, for the required duration.

The overall fire water demand for a period of 1hour 9mins and the required foam
concentrate was evaluated as 1767m3 and 8.0m3 respectively. The application rate for
cooling tank on fire, adjacent tanks and foam solution are 4.1 l/min/m2, and 4.1 l/min/m2
respectively.

See Fire Water Report CQS-EPR-TS-GEN-RPT-001_Rev 3.0 for details.

The Fire fighting and suppression system designed for this facility are listed below:

 Fire water ring main (10”) distribution system complete with sectioning valves,
hydrants and hose cabinets.
 Foam tank to generate the foam
 Foam monitors
 Foam pourers on product tanks
 Fire water storage tanks
 Fixed water spray systems
 Three diesels driven main fire water pumps (two operating and one on standby
per area)
 Two jockey pumps (Electrical driven, one operating and one on standby) to
pressurize the fire water ring main.
The fire water is sourced from the borehole.

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6.0 SAFETY DESIGN DEVELOPMENT

This revision of the safety design philosophy represents the design of the project at
DED. As the project progresses from this phase through, construction and installation
phase, periodic updates should be carried out to identify hazards that were not earlier
noted and appropriate preventive measures put in place. This shall necessitate
updating this and subsequent version of the safety design philosophy as the case may
be. To ensure specified safety Engineering requirements are met, Engineering review
and HAZOP should be conducted to allow for identification and early incorporation of
preventive and mitigation measures of hazards.

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