Maintaining Passive Fire Protection

Systems in a Petro-chemical Facility

By:

Arthur J. Parker, P.E.

William P. Wheeler, P.E.

Senior Fire Protection Engineers

NACE International Bring on the Heat Conference

New Orleans, LA June 4-6, 2013

Presentation Outline

Plant Safety Audits

Preparation For An Audit

Audit Report

Fire Protection Features Commonly Reviewed

Case Study and Lessons Learned

2

Plant Safety Audit

Auditor will review:

Loss Prevention Program records

Overall plant operations

Personnel training records

Process documents

Operations documentation

Safety plans/hazards identification

Site inspection

3

Plant Safety Audit

Who is the auditor?

Owner/Owner Representative

• Compliance Inspector/Officer

• Outside Inspection Agency

Federal, State, Local Jurisdiction

Insurer

Who the auditor is influences inspection

4

What is Commonly Audited

PQV (Program Quality Verification)

P – Program

Does the loss prevention program cover all

required topics, plant areas, etc.

Q – Quality

Does the program have adequate detail,

technical basis, etc.

V – Verification

Does the audit verify the program is being

implemented as stated 5

3 Keys to Successful Audit

1. Documentation

2. Documentation

3. Documentation

6

Audit Preparation

Process diagrams

PFDs, P&IDs, inventory

MSDS sheets

Up-to-date documentation & records

Pre-Inspection

Regular inspection

and maintenance

7

Audit Report

Issued upon completion of audit

Formal vs. informal – still a business

record

Determined by who the auditor was and

purpose of audit (internal or external)

Dictates response detail

8

Audit Report (Cont.)

Likely contains recommendations

Recommendation tracking system critical

Prepare written response to each

recommendation

Address the hazard identified, not necessarily

the recommendation as worded

Develop SMART plans of action to address

each recommendation

Document, Document, Document

9

SMART Plan

S – Specific

Avoid vague responses

M – Measureable

Able to “measure” completion of action

A – Attainable

R – Relevant

T – Time bound

Set due dates 10

Fire Protection

Features/Systems Audited

Active Systems

Fire Pumps

Water Supply

Monitors

Detection Systems

Suppression Systems

11

Fire Protection Systems

Passive Systems

Passive fire protection systems

• Structural steel protection

• Rated barriers

Plant layout/separation

Drainage/containment

Flammable liquids (quantities, pressures,

types, etc.)

12

Passive Fire Proofing

Documented design basis

Defined hazard areas

Extent of coverage (vertical and horizontal)

Design basis exposure conditions

Required hourly ratings

Documented maintenance records

Manufacturer’s recommended practice

Management of Change 13

Case Study

Small specialty refinery

First plant inspection by outside auditor

Plant audit identified variety of safety

issues

Most notable being deficient structural

steel protection

14

Compromised Steel Protection

Damaged/deteriorated fireproofing

Areas of missing/removed fireproofing

Incomplete installation

Unprotected secondary members and

supports

No documentation to support any specific

fire scenario or exposure duration

15

Remediation Steps

Site visit conducted to:

Document existing structural steel

protection conditions

Gather basic process details

Obtain site plans to identify hazards and

equipment location

Develop additional information required for

refinery audit/hazard scenario development

16

Remediation Recommendations

Determine:

Type of fire exposure (hydrocarbon, jet fire)

Determine hourly fire-resistance ratings

required

Specify appropriate passive fire protection

material (s)

• Availability, cost, application requirements, etc.

Conduct refinery audit

17

Fire Protection Analysis

Establish fire scenario envelope

API 2218 guidelines and any site specific

guidelines

Identify high fire-potential equipment by

semi-qualitative approach

Type and quantities of hazardous liquids

Establish fire scenario envelope

Horizontal and vertical

18

Fire Protection Analysis

Identify structural steel members in fire

scenario envelope

Determine required fire-resistance rating

Identify candidate passive fire protection

materials – concrete, SFRM, epoxy

intumescents, etc.

Develop remediation plan

Include steel prep and application guidelines

19

Fire Protection Analysis

Proposed remedial actions documented

Report submitted to Loss Prevention

Agency for approval

Upon acceptance, remedial actions

initiated and completed

Repairs documented

Establish regular I&M program

20

Summary

Audit intended to review existing

procedures, conditions, documentation

Noted deficiencies need to be addressed

Regular internal audits can identify issues

prior to formal audits

Remediation responses need to be specific

Documentation, Documentation,

Documentation 21