DESIGN BASIS REPORT FOR AUTOMATIC MVWS & FOAM

SYSTEM AT DIGBOI REFINERY

PROJECT: AUTOMATIC MVWS AND FOAM SYSTEM FOR PRODUCTTANKS AT

IOCL DIGBOI REFINERY
OWNER

Indian Oil Corporation Ltd ( Assam Oil Division)

CONTRACTOR

Flash Point Controls Kolkata

DOCUMENT NO FPC- IOCDR – DBR-A4-001 Rev. No. 0

For Approval 0 14.01.17 T.M

Description Revision Date Checked

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INTRODUCTION

IOCL Digboi Refinery has installed Manual MVWS System and Manual Foam System
for the Following Tanks located in three separate dykes.

CRU OFFSITE TANK FARM COMPRISING OF:

Sl. Tank No Type Of Tank Dia.(M) Ht.(M)

No
1 T-568 Floating 9 9
Roof(FR)
2 T-569 Floating 9 9
Roof(FR)
3 T-570 Fixed Cum 9 9
Floating
Roof(FCFR)
4 T-571 Floating 10.5 11
Roof(FR)
5 T-572 Floating 13 10.5
Roof(FR)

COKER NAPTHA TANK FARM I COMPRISING OF :

Sl. Tank No Type Of Tank Dia.(M) Ht.(M)

No
1 T-597 Floating 16 14
Roof(FR)
2 T-598 Floating 16 14
Roof(FR)

COKER NAPTHA TANK FARM II COMPRISING OF:

Sl. Tank No Type Of Tank Dia.(M) Ht.(M)

No
1 T-599 Floating 12 10
Roof(FR)
2 T-600 Floating 12 10
Roof(FR)

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Plant authorities have decided to make the operation of MVWS and Foam System Automatic as
follows.

MVWS System

For this the existing MVWS Headers ( 2 No) for each Tank would be connected to a ring/header
laid outside the dyke , this ring/header would in turn be connected to the existing Fire Water
Header around the dyke at a particular point . There would be a Deluge valve located in between
the existing Fire Water Header around the dyke and the new( proposed) ring/header . The basis of
arriving at the size of the Deluge valve is appended subsequently. The arrangement is depicted in
Drawing No FPC-IOCDR-PI-MVWS-A1-101.

Foam System

For this the Existing Foam Headers would be connected to a common manifold specifically for
each tank. This manifold would in turn be connected to individual deluge valves meant for Foam
System for each Tank which will be in turn connected to the proposed ring/header meant for
MVWS System. There would be a common foam compound storage tank for each dyke. The
basis for arriving at the size of Deluge valve, Ratio Controller and Foam Bladder Tank is
appended subsequently. The arrangement is depicted in Drawing No FPC-IOCDR-PI-FS-A1-
102.

DESIGN BASIS
DESIGN BASIS OF MVWS SYSTEM

MVWS System has been designed in compliance with Clause no. 5.9.2 of OISD 116 and Water
demand for MVWS System in compliance with Clause no 5.9.2 of OISD 116 is as follows.

CRU OFFSITE TANK FARM

Tank Details T-568 T-569 T-570 T-571 T-572

Diameter ( M) 9 9 9 10.5 13
Height ( M) 9 9 9 11 10.5
Type of Tank FR FR FR FCFR FR
Shell Surface Area ( M2) 254.34 254.34 254.34 362.67 428.61
Water Application Density ( LPM/M2) 3 3 3 3 3
Theoretical Water Required ( LPM) 763.02 763.02 763.02 1088.01 1285.83
No of Water Spray Rings ( Existing) 1 1 1 2 2
No of Nozzles for each Tank ( Existing) 19 19 19 40 40
K factor Of Nozzles ( Existing) 51 51 51 51 51
Tentative Actual Water Provided considering 1282 1282 1282 2885 2885
discharge @1.5 Bar to 2.5 Bar ( LPM)
Total Water Requirement for Simultaneous
operation of MVWS System for all Tanks @ 3 9616
LPM/M2 ( LPM)
DV Size ( mm NB) selected for Providing Total 150
Water to all Tanks

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COKER NAPTHA TANK FARM I

Tank Details T-597 T-598

Diameter ( M) 16 16
Height ( M) 14 14
Type of Tank FLR FLR
Shell Surface Area ( M2) 703.36 703.36
Water Application Density ( LPM/M2) 3 3
Theoretical Water Required ( LPM) 2110.08 2110.08
No of Water Spray Rings ( Existing) 3 3
No of Nozzles for each Tank ( Existing) 69 69
K factor Of Nozzles ( Existing) 51 51
Tentative Actual Water Provided considering discharge
@1.5 Bar to 2.5 Bar ( LPM) 5175 5175
Total Water Requirement for Simultaneous operation of 10350
MVWS System for all Tanks @ 3 LPM/M2 ( LPM)
DV Size ( mm NB) selected for Providing Total Water to all 150
Tanks

COKER NAPTHA TANK FARM II

Tank Details T-599 T-600

Diameter ( M) 12 12
Height ( M) 10 10
Type of Tank FLR FLR
Shell Surface Area ( M2) 376.8 376.8
Water Application Density ( LPM/M2) 3 3
Theoretical Water Required ( LPM) 1130.4 1130.4
No of Water Spray Rings ( Existing) 2 2
No of Nozzles for each Tank ( Existing) 32 32
K factor Of Nozzles ( Existing) 51 51
Tentative Actual Water Provided considering discharge 2308 2308
@1.5 Bar to 2.5 Bar ( LPM)
Total Water Requirement for Simultaneous operation of 4616
MVWS System for all Tanks @ 3 LPM/M2 ( LPM)
DV Size ( mm NB) selected for Providing Total Water to all 150
Tanks

DESIGN BASIS OF AUTOMATIC FOAM SYSTEM

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FOAM System has been designed in compliance with Clause no. 6.4, 6.5, 6.8 &6.9 of OISD 116
and Water demand for MVWS System in compliance with Clause no 6.4, 6.5, 6.8 &6.9 of OISD
116 is as follows

CRU OFFSITE TANK FARM

Tank Details T-568 T-569 T-570 T-571 T-572

Diameter ( M) 9 9 9 10.5 13
Height ( M) 9 9 9 11 10.5
Type of Tank FLR FLR FLR FCFLR FR
Seal surface Area ( M2) 20.5984 20.5984 20.5984 NA 30.6464
Liquid surface Area ( M2) NA NA NA 86.54625 NA
Foam Application Density ( LPM/M2) 12 12 12 5 12
Theoretical Foam Solution Required ( LPM) 247.1808 247.1808 247.1808 432.7313 367.7568
No of foam Makers provided( Existing) 2 2 2 1 2
Capacity of Foam Maker ( Existing)( LPM) 225 225 225 450 225
Actual Foam Solution Provided ( LPM) 450 450 450 450 450
Foam Compound Requirement( LPM) @ 3% 13.5 13.5 13.5 13.5 13.5
Foam Compound Requirement for 65 min 877.5 877.5 877.5 877.5 877.5
DV Size Foam System ( mm NB) 80 80 80 80 80
Foam Tank Capacity In Compliance with Clause 6.10 900
of OISD 116 ( L)

Size of Ratio Controller ( mm NB) 65 65 65 65 65

COKER NAPTHA TANK FARM I

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Tank Details T-597 T-598

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Diameter ( M) 16 16
Height ( M) 14 14
Type of Tank FLR FLR
Seal surface Area ( M2) 38.1824 38.1824
Foam Application Density ( LPM/M2) 12 12
Theoretical Foam Solution Required ( LPM) 458.1888 458.1888
No of foam Makers provided( Existing) 3 3
Capacity of Foam Maker ( Existing)( LPM) 225 225
Actual Foam Solution Provided ( LPM) 675 675
Foam Compound Requirement( LPM) @ 3% 20.25 20.25
Foam Compound Requirement for 65 min 1316.25 1316.25
DV Size Foam System ( mm NB) 80 80
Foam Tank Capacity In Compliance with Clause 6.10 1400
of OISD 116 ( L)
Size of Ratio Controller ( mm NB) 65 65

COKER NAPTHA TANK FARM II

Tank Details T-599 T-600

Diameter ( M) 12 12
Height ( M) 10 10
Type of Tank FLR FLR
Seal surface Area ( M2) 28.1344 28.1344
Foam Application Density ( LPM/M2) 12 12
Theoretical Foam Solution Required ( LPM) 337.6128 337.6128
No of foam Makers provided( Existing) 2 2
Capacity of Foam Maker ( Existing)( LPM) 225 225
Actual Foam Solution Provided ( LPM) 450 450
Foam Compound Requirement( LPM) @ 3% 13.5 13.5
Foam Compound Requirement for 65 min 877.5 877.5
DV Size Foam System ( mm NB) 80 80
Foam Tank Capacity In Compliance with Clause 6.10 900
of OISD 116 ( L)
Size of Ratio Controller ( mm NB) 65 65

OPERATION PHILOSOPHY

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 The following would be the sequence of operation in case of Fire in a particular Tank in
any of the dykes .

 Fire is detected by LHS cables installed on the roof of the tank ( Near the Foam Seal).
 The signal is sent to the Fire Alarm Panel located nearby.
 This signal sends a signal to Deluge Valve Control Panel for MVWS system for the tanks
in the particular dyke.
 Solenoid Valve for the Deluge Valve for MVWS system is operated automatically
through built in logic available in Deluge Valve Control Panel.
 This allows the balancing water available on the top of clapper to drain through the open
port of the solenoid valve.
 This causes the deluge valve to open and allows pressurized water available at the
upstream of the clapper to flow through the downstream piping of the deluge valve to the
respective headers for MVWS system of the individual tanks.
 The Water gets sprayed on the tank surface through MVWS nozzles located at regular
intervals on the rings meant for MVWS system around the tank thus resulting in cooling
of the tank.
 As soon as the deluge valve is opened a pressure switch located on the downstream
piping of the deluge valve senses the same and sends a signal “MVWS SYSTEM
OPERATED” to the Fire Alarm Control Panel
 Fire Alarm Panel also sends a signal to the respective Foam Deluge valve control panel
for the tank on Fire.
 Solenoid Valve for the Deluge Valve for Foam system of the particular tank is operated
automatically through built in logic available in Foam Deluge Valve Control Panel.
 This allows the balancing water available on the top of clapper to drain through the open
port of the solenoid valve.
 This causes the deluge valve to open and allows pressurized water available at the
upstream of the clapper to flow through the downstream piping of the deluge valve to the
respective foam solution header for Foam system of the individual tanks.
 Once the main water flow is established and water inlet and foam outlet valves are
opened, the water enters the area between vessel wall and bladder, applying pressure to
the bladder. The foam concentrate is forced out of the bladder through the foam outlet
pipe and into the ratio controller through metering orifice. The concentrate pressure and
water inlet pressure at ratio controller will be same, as the main water supply pressure is
utilized to expel the foam from the bladder. The water flowing through the ratio
controller jet creates a low pressure area common both to downstream water and foam
concentrate. This injects the concentrate in to the ratio controller through an accurate
sized orifice. This ensures correct proportioning over a wide range of flow condition.
 In bladder system, the bladder is used as diaphragm to separate the water and foam
concentrate within the tank. The foam concentrate is injected into the ratio controller
utilizing water
 As soon as the deluge valve is opened a pressure switch located on the downstream
piping of the Ratio Controller senses the same and sends a signal “FOAM SYSTEM
OPERATED” to the Fire Alarm Control Panel.

MAJOR EQUIPMENT AND MATERIAL

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 MS Pipes
 GI Pipes
 Deluge Valve
 Butterfly Valve
 Strainer
 Foam Bladder Tank with connecting accessories
 Ratio Controller
 AFF Foam Compound.( 3 % Concentration)
 Pressure Gauge
 Pressure Switch
 Solenoid Valve
 Deluge Valve Control Panel
 LHS Cable
 Fire Alarm Panel.
 Interconnecting FRLS cables.
 Monitor Modules
 Control Modules

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