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7-32
July 1993 Revised May 1998 Page 1 of 50
Table of Contents
Page 1.0 SCOPE ..................................................................................................................................................... 3 1.1 Definition of Flammable and Combustible Liquids ........................................................................... 3 1.1.1 Flammable Liquids ................................................................................................................. 3 1.1.2 Combustible Liquids ............................................................................................................... 3 2.0 RECOMMENDATIONS ............................................................................................................................ 3 2.1 General Flammable and Combustible Liquid Occupancies ............................................................. 3 2.1.1 Location and Construction ...................................................................................................... 3 2.1.2 Equipment Safeguards ........................................................................................................... 6 2.1.3 Ventilation ............................................................................................................................... 9 2.1.4 Ignition Sources .................................................................................................................... 10 2.1.5 Employee Training and Maintenance ................................................................................... 15 2.1.6 Protection .............................................................................................................................. 17 2.2 Piping Systems ............................................................................................................................... 20 2.2.1 Location and Arrangement ................................................................................................... 20 2.2.2 Pipe Materials ....................................................................................................................... 23 2.2.3 Pipe Joints ............................................................................................................................ 23 2.2.4 Flexibility and Support of Piping Systems ............................................................................ 25 2.2.5 Heating and Insulating Piping Systems ............................................................................... 26 2.2.6 Piping System Control Valves and Safety/Emergency Shutoff Valves ................................ 27 2.2.7 Inspection and Testing .......................................................................................................... 29 2.3 Flammable and Combustible Liquid Transfer Systems .................................................................. 30 2.3.1 Transfer by Pumping ............................................................................................................ 30 2.3.2 Gravity Transfer .................................................................................................................... 31 2.3.3 Inert-Gas Transfer ................................................................................................................ 31 2.3.4 Hydraulic Transfer ................................................................................................................ 32 2.3.5 Loading and Unloading Stations .......................................................................................... 35 3.0 SUPPORT FOR RECOMMENDATIONS ............................................................................................. 37 3.1 Application of Recommendations ................................................................................................... 37 3.1.1 General ................................................................................................................................. 37 3.1.2 Fire Hazard ........................................................................................................................... 38 3.1.3 Piping Systems/Transfer Systems ........................................................................................ 38 3.1.4 Room Explosion Hazard ....................................................................................................... 38 3.1.5 Equipment Explosion Hazard ............................................................................................... 40 4.0 APPENDIX ............................................................................................................................................. 41 4.1 Definitions ....................................................................................................................................... 41 4.1.1 Flash Point ............................................................................................................................ 41 4.1.2 Vapor Pressure ..................................................................................................................... 41 4.1.3 Boiling Point .......................................................................................................................... 41 4.1.4 Fire Point .............................................................................................................................. 41 4.1.5 Flammable (Explosive) Limits/Flammable (Explosive) Range ............................................. 41 4.1.6 Vapor Density ....................................................................................................................... 42 4.1.7 Specific Gravity ..................................................................................................................... 42 4.1.8 Water Soluble (Miscible) Flammable and Combustible Liquids ........................................... 42 4.2 Characteristics of Flammable and Combustible Liquid Fires and Explosions ............................... 42 4.2.1 Characteristics and Types of Flammable and Combustible Liquid Fires ............................. 42 4.2.2 Fire Control and Extinguishment .......................................................................................... 43
1993 Factory Mutual Engineering Corp. All rights reserved. No part of this document may be reproduced, stored in a retrieval system, or transmitted, in whole or in part, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without written permission of Factory Mutual Engineering Corp.
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4.2.3 Characteristics of Flammable/Combustible Liquid Vapor-Air Explosions ............................ 44 4.2.4 Explosion Control and Protection ......................................................................................... 44 4.2.5 Equipment Explosion (Deflagration) Venting Design ........................................................... 45 4.3 Miscellaneous ................................................................................................................................. 49 4.3.1 Sight Glasses ....................................................................................................................... 49
List of Figures
Fig. 1. Preferred Locations for Processes Containing Flammable or Combustible Liquids. ....................... 5 Fig. 2a. Location of Hazardous Area Rated Electrical Equipment for up to 70 gal (265 l) of Flammable/Combustible Liquid in Open Equipment. ................................................................. 11 Fig. 2b. Location of Hazardous Area Rated Electrical Equipment for up to 70 gal (265 l) of Flammable/Combustible Liquid in Closed Equipment. ............................................................... 12 Fig. 3a. Location of Hazardous Area Rated Electrical Equipment for More than 70 gal (265 l) of Flammable/Combustible Liquid in Open Equipment. ................................................................. 13 Fig. 3b. Location of Hazardous Area Rated Electrical Equipment for More than 70 gal (265 l) of Flammable/Combustible Liquid in Closed Equipment. ............................................................... 14 Fig. 4. Buried-Pipe Entrance into Building. .................................................................................................. 21 Fig. 5. Preferred Arrangement for Above Grade Pipe Entrance into Building. ........................................... 22 Fig. 6. Welding Neck Type Flange. .............................................................................................................. 24 Fig. 7. Slip-on Type Flange. ......................................................................................................................... 24 Fig. 8. Compressed Inert-Gas Transfer Method. ......................................................................................... 32 Fig. 9. Hydraulic Transfer Method. ............................................................................................................... 34 Fig. 10. Railcar Loading/Unloading Station-Bonding Arrangement to Prevent Sparks Due to Stray Currents. ................................................................................................................................ 36 Fig. 11. Sprinklered vs. Unsprinklered Flammable/Combustible Liquid Fires. ............................................ 45 Fig. 12. Maximum Pressure Developed During Venting of Gases, With and Without Vent Ducts. ............ 49
List of Tables
Table Table Table Table Construction For Flammable and Combustible Liquid Occupancies (notes 1 & 2). ...................... 5 Sprinkler Protection for Occupancies Utilizing Flammable/Combustible Liquids. ........................ 18 Space Separation for Flammable/Combustible Liquid Loading/Unloading Stations. ................... 35 The volume of a stoichiometric vapor-air mixture that may be produced from either 1 gallon or 1 liter of some common flammable liquids. (Note: these values are based on complete vaporization of the liquid.) ............................................................................. 40 Table 5. Heat of Combustion for Representative Materials. ....................................................................... 43 Table 6. Explosion Venting Constants. ....................................................................................................... 46 Table 7. Venting Constants for Other Vapors and Gases. ......................................................................... 47 1. 2. 3. 4.
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1.0 SCOPE This loss prevention data sheet provides recommendations for the prevention of and protection against fires and explosions in occupancies handling, processing, or transferring flammable or combustible liquids. Data sheets covering specific occupancies may supersede this data sheet. Additional recommendations may be needed to provide adequate prevention and protection features for a chemical process plant with the potential for hazardous chemical reactions, three dimensional fires, or operating pressures in excess of 100 psig (7 bar g). Refer to section 3.1 for guidelines on applying recommendations. International standards may be applied, when required, instead of referenced United States standards (i.e., ASTM, ASME, etc.). NFPA 30, Flammable and Combustible Liquids Code, also covers this material. 1.1 Definition of Flammable and Combustible Liquids
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2.1.1.1 Flammable and combustible liquid operations that create a fire and/or an explosion hazard should be located as follows to reduce the exposure to important buildings or facilities and limit exposure to the flammable/combustible liquid operations from fires originating elsewhere (listed in order of descending preference; see Figure 1, Table 1): a. Detached outside location at least 75 ft (23 m) away from an important building or facility. A 50 ft (15 m) separation is acceptable when only a fire hazard exists or an explosion hazard exists with less than 1500 gal (6 cu m) of liquid. (Fig. 1, Location 1) b. Along an exterior wall of an important building (preferably at a corner to limit exposure and increase available vent area). (Fig. 1, Location 2) c. Inside an important building on the first floor, either at an exterior corner or along an exterior wall. Avoid locations in basements, below-grade spaces or on upper floors of multistory buildings. If such locations are unavoidable, the floor of the room should be completely cut off (i.e., no openings in the floor to the floor or space below, to prevent liquid or vapor escape) and liquid tight. An acceptable alternative for rooms with small spaces below is to completely fill in the space with a noncombustible material (e.g., fiberglass, mineral wool, earth). (Fig. 1, Locations 3 and 4) 2.1.1.2 Avoid below grade locations for equipment and piping containing flammable and combustible liquids to help ensure adequate access for manual fire fighting efforts. 2.1.1.3 To limit the potential fire and explosion hazards created by flammable/combustible liquid occupancies, apply the construction features listed in Table 1 to both the exposing building/room and exposed important buildings. Table 1 applies if both the exposing building/room and the exposed building are adequately sprinklered and adequate damage limiting construction, designed in accordance with Data Sheet 1-44, Damage-limiting Construction, is provided when an explosion hazard exists. If the exposing building is not sprinklered (low value building, Location 1 only) and the quantity of flammable or combustible liquid in the building is more than 1500 gal (6000 l), apply spacing and construction recommendations listed in Data Sheet 1-20, Protection Against Fire Exposure, using exposure A (Tables 2 through 7). Construction features shown in Table 1 still apply to the exposing building when an explosion hazard exists. If the exposing building is not sprinklered (low value building, Location 1 only) and quantity of flammable or combustible liquid in the building is less than 1500 gal (6000 l), apply spacing and construction recommendations listed in Data Sheet 1-20, using exposure B (Tables 2 through 7). Construction features shown in Table 1 still apply to the exposing building when an explosion hazard exists. 2.1.1.4 For interior locations with flammable/combustible liquids having a flash point below 200F (93C), provide at least a one hour fire-resistant partition to cut off the flammable liquid occupancy from surrounding occupancies (Table 1). Other recommendations may exist for specific occupancies (covered by occupancy specific data sheets). If unheated combustible liquids with flash points above 200F (93C) are in use, the water supply is adequate, and no high-value occupancies are exposed, a curb surrounding the combustible liquid operation is acceptable in lieu of a fire rated partition. The curbing should be designed for a spill from largest vessel or container plus a 2 in. (51 mm) freeboard in accordance with Data Sheet 7-83, Drainage Systems For Flammable Liquids, (criteria for areas with containment but no drainage).
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Fig. 1. Preferred Locations for Processes Containing Flammable or Combustible Liquids. (Table 1)
Table 1. Construction For Flammable and Combustible Liquid Occupancies (notes 1 & 2). Hazard Type refer to Section 3.1 for definitions Cutoff Room/Building Construction (note 3)
A PV PR PV PR LW FR LW FR B PV PV PV PV Roof (note 4) PV LW PV LW Any
Location
Distance x ft (m) >75 (23) 10-75 (3-23) > 50 (15) 10-50 (3-15) > 50 (15) < 50 (15) > 25 (8) < 25 (8)
LW
LW
Vertical Exposure Protection: PR and 1 hour fire rated for 10 ft (3 m) above exposure. Vertical Exposure Protection: Any
DNA
1. This table assumes adequate sprinkler protection is provided in the Main Building and the exposure. Table also assumes damage limiting construction is designed in accordance with Data Sheet 1-44. 2. If sprinkler protection is not provided in the exposing building (i.e., low value building), use Data Sheet 1-20 (applies to Location 1 only). Use the following exposure rating in Tables 27 of Data Sheet 1-20: Exposure A for quantities greater than 1500 gal (6 cu m). Exposure B for quantities less than 1500 gal (6 cu m). Construction features for the exposing building still apply when an explosion hazard exists. 3. The types of construction are defined as follows: LWlight weight/noncombustible; PVpressure venting; NCnoncombustible; PRpressure resistant. FR1 hour fire rated; 4. Pressure resistant construction should also be provided for floors that have spaces below. Roof construction should meet the requirements listed in Data Sheet 1-44. 5. For <10 ft (3 m) with an explosion hazard, use Location 2, Explosion Hazard. 6. For abutting structures with a fire hazard only, use Location 1, Fire Hazard, <50 ft/<25 ft (15 m/8 m).sprinklered and adequate damage limiting construction, designed in accordance with Data Sheet 1-44, Damage-limiting Construction, is provided when an explosion hazard exists. 1993 Factory Mutual Engineering Corp. All rights reserved.
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2.1.1.6 Provide emergency drainage and/or containment for all flammable/combustible liquid areas protected by water fire suppression systems. Determine the need for drainage and/or containment using Data Sheet 7-83, Drainage Systems For Flammable Liquids, Figure 1. The design of the drainage/containment system or a possible alternative to adequate drainage should be in accordance with Data Sheet 7-83. Curbs and floors in flammable/combustible liquid areas should be watertight. The surface grade around flammable/ combustible liquid areas should direct possible liquid releases away from important buildings. Arrange drainage systems to prevent flammable vapors from backing up into buildings or rooms that are tied into those systems. One method of accomplishing this is the use of trapped drains. Provide this arrangement for all buildings/rooms with drains that are tied into a drainage system that can handle flammable/ combustible liquids regardless of the occupancy in that room/building. 2.1.1.5 When a flammable/combustible liquid occupancy creates a room explosion hazard (see section 3.1.4), provide damage limiting construction as recommended in Table 1 and Data Sheet 1-44, Damage Limiting Construction. If a mist explosion hazard exists, refer to Data Sheet 1-44, Table 4, to design the explosion venting. When damage limiting construction is not possible for small rooms that create a severe exposure to high value adjoining occupancies, consider an explosion suppression system. Install the system in accordance with Data Sheet 7-17, Explosion Protection Systems
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and pressure, replace at regular intervals as determined by processing conditions. h. Rotameters should be armored and arranged so only a sample of the flow is directed through the glass reading chamber instead of the entire stream. Vents on air releases used in conjunction with some metering devices should be piped to outdoor locations to prevent the release of flammable or combustible liquids in the event of meter failure. i. Conduct instrument maintenance, including tightening bolts and replacement, only when the associated equipment or piping has been shut down and depressurized. Equipment containing flammable liquids or gases should be emptied and purged. 2.1.2.4 Flammable or combustible liquid handling and processing equipment that, under normal operating conditions, have the potential for a vapor-air explosion or mist explosion within the equipment (i.e., equipment explosion hazardsee section 3.1.5) should be protected by one of the following methods (listed in order of preference): a. Provide explosion venting designed to limit the pressure developed by an explosion to approximately 133% of the equipments yield strength (stress). If damage to the equipment creates a significant exposure (i.e., high value equipment or difficult to replace), design the explosion venting to limit the pressure development to approximately two thirds (23) of the equipments yield strength (stress) (i.e., prevent permanent equipment deformation). Equipment explosion venting calculations are presented in the Appendix (Section 4.2.5). The initial pressure of the equipment must be considered when calculating the needed vent size. b. Design the equipment to contain the maximum expected pressure due to a vapor-air explosion. The maximum pressure should not exceed 133% of the equipments yield strength (stress). To prevent permanent equipment damage, the maximum pressure should not exceed two thirds (23) of the equipments yield strength (stress). Most vapor-air explosions will produce a maximum pressure of approximately nine times the initial absolute pressure in the equipment (this applies to equipment operating at atmospheric or at elevated initial pressures). c. Provide a gas inerting system designed in accordance with Data Sheet 7-59, Inerting and Purging, that is arranged to prevent the creation of a flammable vapor-air mixture. The inerting system should have a reliable inert gas supply. Equipment operators should be well trained on the importance and function of the inerting system. d. An explosion suppression system, designed in accordance with Data Sheet 7-17, Explosion Protection Systems, should be provided on high value equipment, equipment that exposes high value processes, or equipment with frequent explosions, when either explosion venting, containment, or inerting cannot be provided. 2.1.2.5 Provide purging or ventilation systems for equipment with a vapor-air explosion hazard to reduce the risk of creating a vapor-air mixture in the flammable (explosive) range (not needed on inerted equipment). Design purging systems in accordance with Data Sheet 7-59, Inerting and Purging. Ventilation systems should be designed in accordance with Data Sheet 6-9, Industrial Ovens and Dryers. Utilize purging to avoid passing through the flammable (explosive) range of the flammable vapor during start-up or shutdown operations. Design ventilation systems to limit flammable vapor concentrations to less than 25% of the lower flammable (explosive) limit (these systems are normally found in ovens and dryers). 2.1.2.6 Supports for important equipment or equipment containing flammable/combustible liquids (e.g., mixing tanks, storage tanks) that are blocked from ceiling sprinkler discharge (i.e., equipment that is wider than 3 ft (0.9 m) or 10 sqft (0.9 sq m) in area) should be protected against potential failure due to the high temperatures created by pool fires. Use automatic water spray or sprinklers, arranged to protect the supports, in rooms without a room explosion hazard. Use reinforced concrete or protected steel supports when a room explosion hazard exists or as an alternative to water spray or sprinklers. 2.1.2.7 Tanks, mixers and other equipment to which flammable or combustible liquids are transferred should be arranged to prevent accidental overflow. One or a combination of the following methods or equivalent should be used (listed in order of preference): a. Provide a trapped overflow drain leading back to the source of supply or to a point of safe discharge. The capacity of the overflow drain should be at least equal to that of the fill pipe.
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b. A liquid level-limit switch arranged to stop the liquid flow by closing a valve or stopping the pump should be provided. An audible alarm may be used as a first warning that is followed by shutdown of the liquid flow. The liquid level-limit switch should be FMRC-Approved. This arrangement is acceptable if the equipment normally operates under pressure so that an overflow drain is not practical but overflow is possible during filling because of open manholes or sampling connections. This may also be used in conjunction with an overflow drain (provide an alarm to prevent overflow). The use of weigh tanks, measuring tanks, and dispensing meters to accurately provide a measured quantity of liquid to a tank will assist in the prevention of overflows. Arrange weigh tanks and measuring tanks to prevent overflow (using either a or b). The use of a dispensing meter does not eliminate the need to follow recommendations a and b above. 2.1.2.8 Provide overflow protection and emergency bottom drains for open top tanks to prevent overflow due to sprinkler discharge and hose streams and to remove the exposed flammable/combustible liquid from a fire area. The overflow protection and emergency bottom drains should be designed in accordance with Data Sheet 7-9, Dip Tanks. Sprinkler discharge overflow protection may be omitted if the exposure created by spilling flammable/combustible liquids is limited and one of the following is provided: a. The tank or equipment is equipped with automatic closing covers or normally closed covers. b. The liquid in the tank has a flash point above 200F (93C). c. The tank has a capacity of less than 100 gal (380 l) and there is less than 20 sq ft (1.9 sq m) of exposed surface. Provide at least 6 in. (150 mm) of freeboard on tanks without overflow protection. 2.1.2.8.1 Emergency bottom drains may be omitted if the exposure created by burning flammable/ combustible liquids is limited and one of the following exists: a. The liquid has a flash point greater than 200F (93C). b. The tank has a capacity of less than 500 gal (1900 l) and is located on the first floor. c. The tank has a capacity of less than 150 gal (600 l) and is located on an upper floor. 2.1.2.9 Equipment heating should be provided by steam, hot water, organic heat transfer fluid (see Data Sheet 7-99) or other means not requiring an open flame. Arrange heating equipment for automatic control. Provide a high temperature interlock arranged to provide an audible alarm and shut down the heating equipment. Equipment and process temperatures should be continuously monitored by the operator. Maximum equipment temperatures should be below the liquids autoignition or autodecomposition temperature. 2.1.2.10 Flammable/combustible liquid storage should be cut off from points of use (e.g., manufacturing area). The quantity of flammable/combustible liquid in areas where they are used should be limited to one shifts needs (approximately 100 gal (400 l) or as specified by other specific data sheets). 2.1.2.11 Use drum pumps (preferred, easy control of liquid discharge) or self-closing faucets (gravity driven, less control with failure of faucet), where permitted, for drums arranged for dispensing flammable and combustible liquids. Use drip cans below faucets with on-side dispensing operations of Class I flammable liquids (in areas where the ambient temperature can approach 100F (38C) include Class II combustible liquids). A shallow metal drip pan is acceptable for use with Class II and III combustible liquids except as noted above. The drum pumps, self-closing faucets, and drip cans should be FMRC-Approved. 2.1.2.12 Provide safety bungs on drums of Class I liquids arranged for upright dispensing with a drum pump that is not equipped with pressure and vacuum relief vents. If ambient temperatures can approach 100F (38C), safety bung use should include Class II liquids. Also provide safety bungs on drums of Class I, II and III liquids arranged for on-side dispensing. Safety bung use for Class III liquids is intended to prevent possible spillage during on-side dispensing. Safety bungs prevent the creation of vacuum during dispensing, prevent the release of flammable/combustible liquids and their vapors, allow the release of excess internal pressure that can be created when the drum is exposed to a fire (i.e., prevent a BLEVE), and prevent the flashback of released vapor. Attach safety bungs only to the 2 in. (51 mm) drum opening to ensure its proper operation. Provide safety bungs on intermittent drum storage of flammable or combustible liquids located in a dispensing area if the stored drums will be exposed to a spill from the dispensing drum and sprinkler protection in the
1993 Factory Mutual Engineering Corp. All rights reserved.
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area is not adequate for drum storage (Data Sheet 7-29, Flammable Liquids, Table 2) or sprinkler operation may be delayed (e.g., locations under, 20 ft [6 m] high ceilings). Store the drums on the floor, upright and a maximum of one high. If the dispensing area is adequately curbed and drained so a spill will not expose the stored drums, safety bungs are not needed on the stored drums. Drums stored in adequately protected dedicated storage areas do not need safety bungs. 2.1.2.13 Use FMRC-Approved safety cans for handling small quantities of Class I, II, and IIIA liquids. Class IIIB liquids can be handled in nonrated containers. 2.1.2.14 Use FMRC-Approved flammable liquid storage cabinets for storing small quantities (type, quantity and container size is limited by Approval Standard) of Class I, II, and IIIA liquids in manufacturing areas or areas that are not designed for flammable or combustible liquid use. Provide mechanical ventilation in cabinets where flammable vapors may be present (e.g., open containers, dispensing in cabinet). To maintain cabinet integrity, the ventilation ducts should have a fire resistance similar to the cabinet. If ventilation is not needed, keep the two ventilation openings closed to ensure the cabinets fire rating is maintained. 2.1.2.15 Flammable/combustible liquids should be transferred in closed systems. Arrange liquid pumping and piping systems in accordance with recommendations listed in Sections 2.3 and 2.4.
2.1.3 Ventilation
Ventilation systems are designed to confine, dilute and remove the maximum normal amount of flammable vapor released from equipment and handling of flammable and combustible liquids during normal operations. Adequately designed low level ventilation will reduce the chances of a flammable vapor-air mixture accumulating in the process area. Excessive vapor release caused by equipment failure (pipe break, release from a relief valve), accidental discharge of heated flammable/combustible liquids (drum or tank spill), or an uncontrolled chemical reaction (venting a reactor) cannot be adequately safeguarded by the ventilation rates provided below. Designing a ventilation system to remove a large vapor release is outside the scope of this document. 2.1.3.1 Continuous low level mechanical ventilation designed to provide 1 cfm/sq ft (0.3 cu m/min/sq m) of floor area should be provided in rooms or buildings where Class I liquids or liquids with a flash point up to 300F (149C) that are heated above their flash point are used. 2.1.3.2 In addition to providing the design in 2.1.3.1, the exhaust ventilation should confine flammable vapor concentrations exceeding 25% of the lower explosive limit to within 2 ft (0.6 m) of points of release (e.g., open mixing or dip tanks, dispensing stations). 2.1.3.3 Exhaust air should be removed through a system of blowers, fans and ductwork terminating out of doors away from air inlets, doorways and other openings. Exhaust ducts should be constructed of noncombustible materials. Run the ducts as directly as possible to the outdoors with a minimum of bends. Protect long runs of ventilation ducts with the potential for accumulation of combustible deposits in accordance with Data Sheet 7-78, Industrial Exhaust Systems. Exhaust systems for small rooms may consist of a fan installed at floor level arranged to exhaust out of doors (i.e., installed in wall). The ventilation system should take suction within 12 in. (0.3 m) of the floor. Locate intake openings at open tank lips, near equipment or dispensing, and in any pits located within the cutoff room or within 25 ft (8 m) of the operations that produce vapors. Ventilation systems that are arranged to recirculate air into the room should be provided with a FMRCApproved combustible gas detector arranged to stop recirculation and return to full exhaust when the vapor concentration reached 25% of its lower explosive limit (LEL). 2.1.3.4 As a minimum, interlock exhaust fans with equipment power supplies. However, if flammable or combustible liquids are kept in the room or building during idle periods, the exhaust ventilation should operate continuously and be monitored (provide visual or audible ventilation failure alarm at occupied locations). 2.1.3.5 Provide make-up air inlets in exterior walls. Air inlets should be remote from exhaust outlets so that air will sweep through the hazardous area. If gas or oil make-up air heaters are provided, they should be indirect-fired and properly safeguarded.
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If make-up air is taken from other plant areas, those areas should be free of flammable or combustible liquids. Install automatic closing fire dampers or doors at make-up air inlet openings in interior fire walls or partitions. The dampers or doors should have a fire rating equal to that of the walls. 2.1.3.6 For unheated liquids with a flash point greater than 100F (38C) and heated liquids with a flash point greater than 300F (149C), provide natural draft ventilation arranged to provide 1 sq ft (0.1 sq m) of free inlet and outlet opening per 500 sq ft (47 sq m) of floor area.
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Yes/No
Electrical Equipment Needed in Pit Class I Division 1 Class I Division 1 Class I Division 2 Ordinary
Fig. 2a. Location of Hazardous Area Rated Electrical Equipment for up to 70 gal (265 l) of Flammable/Combustible Liquid in Open Equipment.
2.1.4.4 When heating rooms or buildings containing a flammable or combustible liquid occupancy, use a system that does not introduce an ignition source (e.g., steam or hot water, organic heat transfer oil, or hazardous location rated electric heating). Direct natural gas/fuel oil-fired make-up air heaters are acceptable if the heating unit is located outside the room or building and there is no air recirculation. Heating equipment temperatures should be below the auto-ignition point of the liquids present in the room. If Class I liquids are present, the heaters should be at least 4 ft (1 m) above the floor level. 2.1.4.5 Arrange all equipment that may produce sparks (electrical, static, mechanical, or friction), open flames, or hot surfaces to prevent or strictly limit contact with flammable/combustible liquids or their vapors. Equipment that, over time, may produce sparks or hot spots due to wear (e.g., rotating equipment such as motors, agitators, pumps, etc.) should be maintained on a strict schedule. Equipment or piping that create hot surfaces (e.g., steam pipe) should be avoided in areas with piping systems containing unusually low ignition temperature liquids, such as carbon disulfide.
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1. Class I, Division 2 2.
Yes/No
Fig. 2b. Location of Hazardous Area Rated Electrical Equipment for up to 70 gal (265 l) of Flammable/Combustible Liquid in Closed Equipment.
2.1.4.6 Industrial trucks should be properly rated and FMRC-Approved for use in areas requiring Class I Division 1 or 2 electrical equipment. Refer to Data Sheet 7-39, Industrial Trucks, to select the appropriate truck rating. 2.1.4.7 Avoid hot work of any kind in areas handling, processing or storing flammable liquids. Hot Work provides an ignition source in an area where fuel is available in significant quantities and in a readily ignitable form. Ideally, relocate any hot work to a nonhazardous location. When relocation is not possible, a documented Hot Work Permit System is needed. Use a documented permit system to strictly control all hot work operations. The permit is issued only after a complete review of all proposed work, the hazards in the area, and all precautions needed to prevent a fire or explosion. If all of the requirements cannot be met, then the permit should not be issued and the work should not be allowed. Precautions are listed on the FM Hot Work Permit itself. Some of the minimum requirements include: a. Automatic sprinkler protection should be in service. Charged small hose or fire extinguishers should be available at work area. b. Remove flammable and combustible liquid storage from the area. All combustibles within 35 ft (11 m) of the work should be removed or covered with a fire-resistive tarpaulin (see Data Sheet 1-0, Construction Safeguards During Building Construction).
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25 ft (8 m)
No Yes
Electrical Equipment Needed in Pit Class I Division 1 Class I Division 1 Class I Division 2 Class I Division 2 Ordinary
4. No Equipment With Make-and-Break or Sliding Contacts (e.g., motors, switches, receptacles, cutouts, etc.) Equipment Protected Against Physical Damage Lighting Equipment Provided With a Lens to Enclose the Bulb
Fig. 3a. Location of Hazardous Area Rated Electrical Equipment for More than 70 gal (265 l) of Flammable/Combustible Liquid in Open Equipment.
c. Drain all equipment or piping, in the area, of flammable and combustible liquids. Equipment or pipe to be worked on should be steam cleaned or provided with an inert atmosphere to prevent creation of a flammable atmosphere (see Data Sheet 7-59, Inerting and Purging). Piping supplying the area with flammable and combustible liquids should be shut off at the source (valve should be locked shut to prevent unexpected opening). If the piping is to be worked on, it should be blanked off. Check equipment or piping with an FMRC-Approved portable oxygen analyzer (see Data Sheet 5-49, Gas and Vapor Detectors and Analysis Systems) before and during the hot work. This is to ensure that sufficient oxygen to support combustion is not present inside the equipment or piping. d. All permanent storage tanks or piping that cannot be moved or drained must be protected against physical contact and heat from hot work equipment. Preferably all equipment that is within reach of the hot work equipment (grinder, welding rod holder, cutting torch, etc.) will be drained, purged and inerted. If this isnt possible due to the quantities of flammable liquids involved, physical protection can be provided
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> 25 ft (8 m)
Yes/No
Fig. 3b. Location of Hazardous Area Rated Electrical Equipment for More than 70 gal (265 l) of Flammable/Combustible Liquid in Closed Equipment.
by placing welding curtains and temporary barriers between the equipment and the hot work. A careful review of the area is required to insure no vents or other openings are near the hot work that could allow fumes and sparks from the hot work to meet. e. Keep mechanical ventilation in the room/building in operation. Use a portable combustible gas analyzer before and during the work. If any detectable readings are obtained, then work cannot begin or continue until the source is found and suitably mitigated such that the concentration is maintained below 10% of the LEL. f. Provide a continuous fire watch both during and at least 60 minutes after work. Check the area at least hourly for up to three hours after the end of hot work operations. Avoid the use of nonrated electrical equipment in areas containing flammable liquids. If such equipment must be temporarily introduced, view this as hot work and follow the permit precautions. As with other hot work, if the precautions cannot be taken, the permit should not be issued and the nonrated electrical equipment should not be used. For situations where the above steps are not applicable or unusual circumstances are present, consult a specialist in flammable/combustible liquid handling before any hot work is performed.
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Piping containing flammable and combustible liquids should be labeled and color coded. Piping containing specific flammable and combustible liquids should indicate the liquid name and direction of flow. Identification is particularly important where piping passes through walls, at valves and fittings, and at points of use. An acceptable piping identification system is described in ANSI A13.1. Pipe labeling and coding will reduce mix-ups during liquid transfer, prevent mistakes during maintenance operations, and reduce confusion during emergency responses. 2.1.5.7 Establish excellent housekeeping standards for areas storing or handling flammable and combustible liquids. Clean up spills promptly. Keep waste materials in FMRC-Approved oily waste cans. Remove waste daily. Maintain adequate aisles to permit unobstructed movement of personnel and access for fire fighting. 2.1.5.8 Provide a raw materials inspection program to ensure delivery of expected materials and prevent the introduction of foreign or incompatible materials into a storage or distribution system. 2.1.5.9 Management should strictly control all changes or new installations in processes or areas containing flammable and combustible liquids. Conduct a full review of all planned changes by qualified loss prevention consultants as well as other authorities having jurisdiction before the project begins. 2.1.5.10 Establish a complete preventive maintenance program designed to ensure that equipment is operating as it has been engineered to operate. Refer to Data Sheet 9-0, Preventive Maintenance, to evaluate existing programs or as a guide to develop new programs. This program should also include regular recorded testing of safety devices and process control features in accordance with the manufacturers recommendations. Preventive maintenance programs for equipment and areas containing flammable or combustible liquids should include: mechanical and electrical equipment, piping systems (e.g., connect/disconnect points, pumps, flanged fittings, flexible pressure hoses, swing joints, etc.), system control devices (e.g., valves, computer controllers, etc.), and emergency control or relief devices (e.g., emergency shutoff valves, float valves, pressure relief devices, etc.). Follow preventive maintenance schedules closely to prevent the creation of an ignition source (e.g., equipment breakdown and overheating, improperly sealed hazardous area rated electric equipment) or the release of flammable or combustible liquid (e.g., pipe joint failure). Conduct frequent inspections to detect and repair leakage. Use a flammable-vapor detector to locate small leaks (detector should be FMRC-Approved). Prohibit the use of open flames or spark-producing devices. 2.1.5.11 Perform maintenance or repair operations only on equipment that has been depressurized, shut down and drained of any flammable/combustible liquids. This includes tightening or loosening bolts or flanges, packing glands, or making new connections. Piping should be depressurized, drained flushed, purged and inerted before it is opened or tapped. Bolts for flanges or for connections to flanged fittings should be tightened with a torque wrench to ensure proper tightness without overstressing. Prohibit the use of power tools unless the precautions listed in recommendation 2.1.4.7 are strictly followed. Use FMRC-Approved safety tools in areas where a flammable atmosphere may exist. 2.1.5.12 Relocate equipment needing repair or maintenance by use of a cutting torch or other hot work operation preferably to a nonhazardous location. Regardless of where the work is done, the equipment should be drained, flushed, purged, and inerted as necessary to eliminate all flammable and combustible liquids and their vapors. Use an FMRC-Approved combustible vapor analyzer (see Data Sheet 5-49) before and during work to make certain equipment that is not inerted has been fully purged and remains purged of any flammable vapors. Check equipment that is inerted before and during work with an FMRC-Approved oxygen analyzer to ensure a flammable atmosphere is not present. Follow recommendation 2.1.4.7 and Data Sheet 7-59, Inerting and Purging, to ensure all flammable vapors and potential ignition sources have been eliminated. 2.1.5.13 Use an equipment isolation procedure to supervise valves controlling flammable and combustible liquids that are shut off for repair or other maintenance procedures. Equipment isolation procedures should be strictly controlled to ensure equipment repairs/maintenance are complete before flammable/combustible liquids are introduced.
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2.1.5.14 Remove unused piping or tanks. Cap open end pipes promptly. Unused equipment that is not removed should be completely drained and purged of all flammable/combustible liquids and their vapors. The equipment should also be disconnected from any surrounding active equipment and clearly labeled as shutdown to reduce the chances of accidental use. 2.1.5.15 Protect flammable and combustible liquid handling and transfer equipment against external corrosion. Protective coatings for buried tanks and piping should be carefully applied and inspected before they are covered. Conduct regular inspections of the equipment to investigate external corrosion. Increase the inspection frequency of equipment located in corrosive atmospheres.
2.1.6 Protection
2.1.6.1 Provide automatic sprinkler protection over all areas storing, processing, or transferring flammable and/or combustible liquids. Extend the sprinkler protection to the physical limits of the area. The physical limits are defined by at least one hour rated fire walls and curbs. Sprinkler systems over areas defined by curbs only (see Section 2.1.1.4) should extend over and 20 ft (6 m) beyond the curbed area. The sprinkler system should be either a standard closed head, preaction or deluge type. Preaction systems are preferred over dry systems for unheated locations. Install the sprinkler system in accordance with Data Sheet 2-8N, Installation of Sprinkler Systems. 2.1.6.2 Provide sprinkler protection under any obstruction to water distribution that exceeds 3 ft (0.9 m) in width or diameter and 10 sq ft (0.9 sq m) in area (e.g., under large tanks or pieces of equipment, below grated mezzanines) to ensure adequate cooling for steel structures. Spacing below mezzanines should be 100 sq ft (9 sq m) per head. 2.1.6.3 Automatic sprinkler protection may be omitted in building areas that contain no combustibles (including combustible construction) other than flammable or combustible liquid piping if all of the following exist: a. The piping is welded with no flanged joints or has threaded joints that meet the criteria listed in Section 2.2.3.6. Evaluate fire protection requirements for external pipe racks in accordance with Data Sheet 7-14, Protection for Flammable Liquid/Flammable Gas Processing Equipment. b. There are no valves, pumps, or other accessories that are known to be potential leakage points. c. The piping system consists solely of ferrous piping installed as recommended in Section 2.3 of this document. Automatic sprinkler protection may also be omitted in low value buildings (including pump houses, etc.) with flammable and combustible liquid processes that have adequate space separation (see Sections 2.1.1, 2.3.1) from important buildings and structures. 2.1.6.4 Sprinkler spacing should be a maximum of 100 sq ft (9 sq m) when protecting liquids with a flash point less than 200F (93C) or greater than 200F (93C) and heated to its flash point. A maximum spacing of 130 sq ft (12 sq m) when protecting liquids with a flash point greater than or equal to 200F (93C). 2.1.6.5 Automatic sprinkler systems (i.e., wet, preaction, or deluge) should be hydraulically designed as indicated in Table 2. If a dry sprinkler system is provided, increase the sprinkler operating areas by 50%. These tables apply to ordinary manufacturing occupancies that use flammable and/or combustible liquids (no liquid quantity limitations) with no potential for a three dimensional fire. Refer to Data Sheet 7-14 for plants or buildings that are dedicated to flammable/combustible liquid processing (i.e., plants with processes that involve chemical reactions, chemical plants, etc.), any process that creates the potential for three dimensional flammable/combustible liquid fires, or processes that operate at high pressures (pressures approximately 100 psig [7 bar g] or greater) . Sprinkler protection recommendations provided in other FM data sheets that address specific occupancies that use flammable/combustible liquids supersede the recommendations in the document.
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Table 2. Sprinkler Protection for Occupancies Utilizing Flammable/Combustible Liquids. Room/ Liquid Equipment Liquid Flash Heated Explosion Point, To/Above Hazard o F (oC) Flash Point (note 1) Any liquid with an associated room/ equipment explosion hazard or nitrocellulose lacquer
< 100 (38) DNA Yes No Yes > 200 (93) No No No No No No
165 (74) 286 (141) 165 (74) 286 (141) 165 (74) 286 (141) 165 (74) 286 (141) 165 (74) 286 (141) 165 (74) 0.30 (12) 0.30 (12) 0.25 (10) 0.25 (10) 0.20 (8)
8000 (740) 4000 6000 4000 6000 4000 6000 4000 6000 3000 4000 (370) (560) (370) (560) (370) (560) (370) (560) (280) (370)
100200 (3893)
500 (120)
60
1. See Sections 3.1.4 and 3.1.5 for definition of room/equipment explosion hazard. 2. Hose stream demands may need to be increased if shielded areas exist. 3. Water supply durations may need to be increased when local conditions delay fire fighting efforts (e.g., lack of drainage, inaccessible areas, etc.).
Sprinkler protection for flammable/combustible liquid processes and transfer systems may be designed for the surrounding occupancy when one of the following applies: a. The aggregate area of an open tank and its drainboard is less than 20 sq ft (2 sq m). b. The total liquid surface area of an open tank does not exceed 10 sq ft (1 sq m). c. The aggregate liquid capacity within the fire area is less than 70 gal (300 l). The flammable or combustible liquid should be kept in flammable liquid storage cabinets. d. The area contains properly arranged ferrous piping (no valves, manifolds, pumps, or other accessories). 2.1.6.6 Sprinklers provided below open grate mezzanines (no flammable or combustible liquids located above the mezzanine) should be hydraulically designed to provide the same density as recommended for the ceiling over half the recommended area (or the entire mezzanine area; whichever is smaller). These sprinklers should be balanced with the ceiling demand at the point of connection. If flammable liquids are located above the mezzanine, a three dimensional fire potential exists and Data Sheet 7-14 should be used for system design. 2.1.6.7 Spacing of detectors for interior deluge systems (either pilot head, electric, or pneumatic) should be in accordance with Data Sheet 2-8N, 5-3.5 (pilot headssame spacing as sprinklers, electric or pneumatic devices under smooth ceilingsfollow spacing requirements listed in the FMRC Approval Guide for the particular model) or as recommended in data sheets that cover the specific occupancy. Exterior deluge system design should be in accordance with Data Sheet 7-14. Detector spacing for preaction systems (either pilot head, electric, or pneumatic) should be as follows: a. Pilot head spacing should be the same as the sprinkler spacing. Preaction sprinkler systems that use pilot heads should be considered dry systems for design purposes regardless of detector spacing. b. Electric or pneumatic detector spacing should be the greater of one-half the listed linear detector spacing or the full sprinkler spacing. Preaction systems with this detector spacing may be considered wet systems for design purposes. Preaction systems with a detector spacing greater than the above spacing should be considered dry systems for design purposes. The spacing should never exceed the devices listed spacing (e.g., FMRC-Approval Guide listing).
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2.1.6.8 Sprinkler piping, valves, and fittings exposed by occupancies that create an explosion hazard should be protected in accordance with Data Sheet 2-8N, Section 3-10, and Data Sheet 7-14. 2.1.6.9 Automatic sprinkler protection may be supplemented with a fixed special protection system (local or total floodinggaseous, dry chemical, water spray) to limit the exposure created by a potential flammable/ combustible liquid fire. A special protection system should be provided to: a. Limit fire damage and downtime for high value processes. b. Limit exposure to high value surrounding occupancies that are susceptible to smoke and water damage. c. Provide local protection for open tanks that are not accessible to fire fighting with portable extinguishers. d. Limit the exposure created by inadequate space separation between important buildings or processes and flammable/combustible liquid operations (e.g., loading and unloading stations, piping systems, etc.). The special protection system should be FMRC-Approved and designed in accordance with the applicable FM data sheet. 2.1.6.10 When an open (deluge) or closed-head AFFF (aqueous film forming foam) sprinkler system is provided as an alternative to a standard sprinkler or deluge system, the following design criteria should be used (not acceptable in areas with a three dimensional fire potential or warehouse/storage areas): a. Closed or open-head AFFF sprinkler systems should be hydraulically designed to provide either the density listed in Table 2 or the minimum required density provided in the Approval Listing, whichever is larger. The AFFF concentrate injection percentage should be in accordance with the Approval Listing. The closed-head systems should be designed to deliver this density over the demand area listed in Table 2. This protection is acceptable with or without adequate drainage (except when superseded by a specific occupancy data sheet). b. Exterior hose stream demand and water supply duration should be as recommended in Table 2. c. Areas with adequate drainage in accordance with Data Sheet 7-83 should have at least a 10-minute supply of AFFF concentrate provided. Areas without adequate drainage should have at least a 20-minute supply of AFFF concentrate provided. The supply should be based on the sprinkler system design requirements, hose stream design requirements and the required concentrate injection percentage provided in parts (a) and (b) above. d. Adequate containment designed in accordance with Data Sheet 7-83 should be provided when adequate drainage is available. If adequate drainage is not available, containment should be designed to hold sprinkler and hose stream discharge for the full 20-minute foam concentrate duration. e. The AFFF concentrate should be compatible and FMRC-Approved for the flammable or combustible liquid being protected. The AFFF delivery system (proportioning equipment, sprinklers) should be FMRCApproved. f. The AFFF system should be installed in accordance with NFPA 16, Deluge Foam-Water Sprinkler and Foam-Water Spray Systems, and NFPA 16A, Installation of Closed-Head Foam-Water Sprinkler Systems. 2.1.6.11 Portable extinguishers should be provided for areas (interior and exterior) utilizing or handling flammable and combustible liquids. Extinguishers should be either carbon dioxide, dry chemical, or AFFF type. Refer to Data Sheet 4-5, Portable Extinguishers, to determine effective sizes and locations for the extinguishers. Extinguishers should be FMRC-Approved. Protect extinguishers located outside against freezing. 2.1.6.12 Provide small hose (112 in. [38 mm]) stations with combination spray/ solid stream nozzles in areas utilizing or handling flammable and combustible liquids. Space hose stations to allow full coverage of the area being protected. Add a water demand of 50 gpm (11 cu m/h) to the sprinkler demand for a single hose station (100 gpm [23 cu m/h] should be added for more than one hose station). 2.1.6.13 Manual protection consisting of yard hydrants should be located within 200 ft (60 m) of all outside flammable and combustible liquid handling and process areas (e.g., pump houses, loading and unloading stations, valve-manifold houses, process structures, etc.). Provide manual foam protection for critical process or handling areas containing liquids with flash points below 200F (93C). Manual foam protection can be
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provided by a fixed water spray system, fixed monitor nozzles, or mobile monitor and hose nozzles. Design the system in accordance with Data Sheet 4-7N, Foam Extinguishing Systems. 2.2 Piping Systems
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a. Provide drainage in accordance with Data Sheet 7-83, Drainage Systems for Flammable Liquids. The trench may be used to direct the liquid to a collection point that does not expose the building (e.g., pitch the trench to an exterior collection point so a spill that collects in the trench will be directed out of the building). b. Provide positive exhaust ventilation throughout the trench when the piping system is transporting liquids with a flash point below 100F. Alternatives to providing ventilation are filling the trench with sand (this will eliminate the need for drainage as well). c. If the trench passes below a cutoff wall (e.g., enters a flammable liquid room from an adjacent area), cut the trench off at the wall with a liquid tight noncombustible barrier. The section of trench outside the area using the flammable/combustible liquids does not require drainage or ventilation if it is welded piping only (no leakage pointsvalves, flanged joints, etc.). Protect the section of trench inside the room or trench areas containing potential leakage points as stated in parts (a.) and (b.) above. 2.2.1.8 If piping is located inside a building and is below grade (e.g., basement areas) or is inaccessible (e.g., vacant below grade spaces) provide one of the following: a. Enclose the pipe in a larger pipe throughout its entire length (Fig. 4). Weld the larger pipe at joints. Provide a means of checking for leaks (e.g., provide a low point drain that is accessible for inspection on regular intervals).
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b. Enclose the pipe in sealed ductwork throughout its entire length. Arrange the ductwork to permit inspection for leaks and allow drainage of potential leaks to a collection location (e.g., tank or flammable/ combustible liquid drainage system). c. Basements or below grade spaces containing flammable or combustible liquid piping should be provided with automatic sprinkler protection (Table 3), adequate drainage (per Data Sheet 7-83), and a low level continuous mechanical exhaust ventilation system for the entire space. Design the ventilation system to provide 0.5 cfm/sq ft (0.15 cu m/min/sq m). Natural ventilation is acceptable for pipe containing liquids with a flash point greater than 100F (38C). 2.2.1.9 Piping should enter buildings above grade. Buried piping should be brought above grade before entering a building as shown in Figure 5. The piping should be adequately protected against damage due to building settlement. Where flammable or combustible liquid piping enters a building below grade, seal all other nearby openings in the foundation. 2.2.1.10 Enclose piping in a pipe sleeve where the piping passes through exterior walls and foundations. Seal the opening between the sleeve and the pipe. Extend the sleeve to the exterior of the wall or foundation at least 2 in. (51 mm) or 18 in. (460 mm) respectively. (Figs. 4 & 5)
Fig. 5. Preferred Arrangement for Above Grade Pipe Entrance into Building.
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2.2.1.11 Arrange piping systems to permit drainage of its content during maintenance operations (repairs, cutting and welding, etc.). This can be accomplished by pitching pipe back towards the supply, providing low point drains, and providing flanged connections at various locations to permit disconnection and blanking of the pipe.
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b. Flanges should be welding-neck type (flange is butt welded to pipe endsee Figure 6). A double welded slip-on type flange (flange slips over pipe end and is welded outside and insidesee Figure 7) is acceptable for use in systems that are noncyclic and have operating pressures less than 100 psig (7 bar g).
c. Design flanges on lined pipe (i.e., plastic, glass, etc., in steel pipe) to prevent leakage in the event of lining failure (e.g., fire exposure to pipe melts plastic lining). d. Consider high integrity or protected flanges (i.e., flanges designed or protected to prevent leakage or full failure) when the exposure created by leakage (fire or explosion) is significant (e.g., spray fire exposure to high value occupancies, flange failure would create explosion potential). 2.2.3.3 Bolting materials for flanges should be alloy steel conforming to ASTM A193, Alloy Steel Bolting Materials for High Temperature Service, Grade B-7 or equivalent. Nuts should be alloy steel conforming to ASTM A194, Carbon and Alloy Steel Nuts for Bolts for High Pressure and High Temperature Service. Bolt and nut dimensions and threads should conform to nationally recognized codes. Existing installations with carbon steel and wrought iron bolts are acceptable in sprinklered areas or in outside areas with limited exposures. Make the effort to replace the bolts during maintenance of the joints or if the bolts are corroded. 2.2.3.4 Gaskets for use with flanged joints should be compatible with the flange type being used. Consider the following factors when choosing a gasket material: a. Chemical compatibility with the liquid in use. b. Strength and temperature limitations (adequate for maximum possible system pressure and temperature as well as system pressures when exposed by external fire). c. Resistance to leakage or total failure. d. Resistance to cold flow.
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e. Resistance to decomposition or melting with an external fire exposure (e.g., noncombustible, high melting pointgreater than 1200F [650C]). 2.2.3.4.1 Use one of the following types of gasket for flammable and combustible liquid service: a. Spiral-wound stainless steel, Monel, copper, Inconel 600, or equivalent metallic gasket with graphite, ceramic, or equivalent filler. b. Metal ring-joint gasket consisting of dead-soft aluminum, Monel, copper, or equivalent. c. Graphite gasket without organic fillers or resins. 2.2.3.4.2 Other gasket materials consisting of fiber-sheet, paper, vegetable fiber, plastic, cork, lead, rubber, Teflon, or equivalent are tolerable in existing systems located in sprinklered areas if all of the following are true: a. The operating pressure is less than 100 psig (7 bar g). b. The system is noncylic. c. The potential exposure created by a gasket failure is limited. d. The joints are outside and either underground or aboveground with limited exposure. 2.2.3.5 Join nonferrous metallic piping with flanged, brazed or flared connections. Brazing alloys should have a minimum melting point of 1000F (535C). Do not use fillet-brazed joints or soldered joints. 2.2.3.6 Avoid threaded joints. New systems containing liquids with flash points of 200F (93C) and above or existing systems (any flash point) with threaded joints can be considered tolerable when all of the following are true: a. The exposure created by leakage is minimal. b. The piping system has an operating pressure less than 100 psig (7 bar g). c. The piping system has limited leakage (constant repairs for leakage would indicate a change in joint type is needed). d. Operating conditions are not cyclic. e. Operating conditions do not create corrosion problems. If the piping creates a significant exposure, severe cyclic conditions exist or corrosion problems exist, replace the threaded connections with butt welded joints. Piping systems with high pressures (greater than 100 psig [7 bar g]) or leakage problems should have the threaded joints seal welded. A combination of leakage problems and high system pressures in a piping system should have threaded joints replaced with butt welded joints.
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a. Design pipe hangers to support the full weight of the system including all live loads (e.g., content, snow), dead loads (e.g., pipe, valves, insulation), and test loads (e.g., test liquid weight). b. Design pipe hangers for expected dynamic effects (e.g., hydraulic shock, wind loads, vibration) and potential thermal expansion and contraction loads. c. Arrange pipe hangers to prevent excessive vibration and strain on connecting equipment. d. Limit horizontal pipe spans to reduce stress on pipe walls. Long horizontal spans should be supported from cables or trusses. e. Arrange hangers to prevent stress on joints and pipe sagging. f. Hangers and anchoring devices should consist of high melting point, noncombustible materials or be insulated against possible exposure fires. g. Follow manufacturers recommendations closely for supporting specialty piping. 2.2.4.4 Provide flexible hose connectors in piping systems to prevent dangerous stresses due to vibration, settling, or thermal change. Provide the following material and installation features to ensure adequate hose strength/durability and protection against physical damage: a. Flexible hose should be constructed of high strength, noncombustible material that is resistant to decomposition or melting when exposed to an exposure fire and compatible with the liquid in use. All-metal construction consisting of materials such as steel, Monel, stainless steel, brass, bronze, or an equivalent material are preferred. Reinforced rubber hose with a synthetic liner and a metal-braid covering is acceptable when needed to meet operational requirements. Do not use soft rubber, plastic, or other unreinforced or unprotected combustible tubing. b. The hose should only be bent in one plane without subjecting it to tensile, torsional, or excessive bending stresses. c. Protect the hose against mechanical damage. d. Hose joints should comply with all rigid pipe joint recommendations (section 2.2.3). e. Hose and fittings should have a bursting strength that is greater than the maximum expected working pressure with a safety factor of at least 4. 2.2.4.5 Arrange piping systems located in areas exposed by earthquakes in accordance with Data Sheet 1-2, Earthquakes.
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d. Enclose the pipe and steam-tracing in insulation. 2.2.5.4 An electric heating cable system should be arranged as follows: a. Heating cable should be fastened along the pipe or spirally wound around the pipe. Enclose the pipe and cable in insulation. b. Heating cable should be continuous (no splices). Electrical connections should be visible for inspection. c. Provide individual thermostat controls for each cable section. Fuses or fused disconnect switches of as low a rating as practical should also be provided. d. Electrical equipment (thermostats, plug assemblies, and switches) exposed to various weather conditions should be enclosed in weatherproof housings. All sparking equipment (i.e., equipment with make-and-break contacts) should be well separated from the pipeline and locations requiring hazardous area rated electrical equipment. e. All electric heating cable equipment should be FMRC-Approved. 2.2.5.5 An impedance heating system should be arranged as follows: a. Systems should be installed and tested as complete units by the manufacturer or other qualified installer. The installation should conform to the requirements of the authority having jurisdiction and Article 427Fixed Electric Heating Equipment For Pipelines and Vessels, of the National Electric Code (1990 or current edition). b. Piping sections that are heated should be insulated from unheated sections with electrically nonconductive fittings to confine the current paths and to eliminate any current leakage at hazardous locations. c. Provide an automatic high-temperature-limit cutoff switch in each circuit of each system to prevent overheating of liquid in event of failure of the operating temperature control thermostat. d. Enclose all parts of the piping and fittings in electrical and thermal insulating material to prevent accidental grounding of the system. Provide a ground fault interrupt (GFI) device for the power supply of all impedance heating systems. e. Locate all sparking equipment (e.g., switches, transformers, contacts) well away from the pipeline and areas requiring electrical equipment rated for hazardous locations. f. Test the heating system periodically to ensure its continued proper operation. All maintenance on the system should be conducted by trained employees or contractors. 2.2.5.6 Insulation provided on the piping system should be noncombustible. Provide nonabsorbent insulation (e.g., closed cell cellular glass) near flanged fittings or other potential leakage points (e.g., valves, pumps). Any type of insulation (e.g., calcium silicate, glass fiber batts, mineral wool, etc.) is acceptable over welded pipe.
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b. Valves may be either manually operated at point of use or remotely operated depending on complexity of the system. Remotely operated valves should fail in a safe position. c. Arrange valves to ensure adequate control of liquid direction and flow rate. The valve arrangement should also minimize the potential for improper system operation (e.g., allowing liquid flow to the wrong tank, permitting too high a liquid flow rate, etc.). Proper valve operation can be accomplished through the use of check lists for manual system operation and through process control systems for remote operation. Thorough employee training is needed for either approach. d. Arrange control valves to isolate important equipment to permit maintenance operations or replacement. e. Control valves that may be exposed to severe fire conditions (e.g., valves located in a flammable liquid room) where loss of their function could significantly increase the exposure (e.g., valve controlling flammable liquid flow from the bottom of a tank where valve failure would release the tank contents) should be a FMRC-Approved firesafe shutoff valve. 2.2.6.4 Safety/emergency shutoff valves should be either diaphragm, solenoid, or fusible-element (weight or spring operated) type. Positive displacement pumps may also be used as a safety/emergency shutoff. The valves should be FMRC-Approved. Valves that may be exposed to a flammable/combustible liquid fire should be FMRC-Approved fire safe shutoff valves. 2.2.6.5 Arrange safety/emergency shutoff valves to permit complete shutdown of liquid flow during a fire and to limit the quantity of liquid released in the event of accidental escape. In general this can be accomplished by isolating the liquid supply and shutting off liquid at the various points of use. The actual number and location of safety/emergency shutoff valves will vary depending on the piping system size, complexity and potential exposure created by a release. All piping systems containing flammable/combustible liquids should at least have safety/emergency shutoff valves in the following locations: a. On discharge lines of interior or exterior tanks (aboveground or underground), arranged for transfer by gravity, centrifugal pump, inert gas pressure, or other means that provide continuous pressure on the system. b. On bottom-discharge lines of exterior aboveground tanks feeding a positive displacement pump when multiple tanks are located in the same area (e.g., two or more tanks in a diked area or a single tank in a diked area that is not accessible during a fire) to permit supply shutdown in the event of a leak at the pump. A single exterior tank (e.g., single tank in a diked area that is accessible) feeding a positive displacement pump may have a manually operated valve on the bottom-discharge line. c. On bottom-discharge lines of interior tanks feeding positive displacement pumps to permit supply shutdown in the event of a leak at the pump. d. At points of use such as dispensing operations or delivery lines to equipment. Valves may be located on each feed pipe to a piece of equipment/dispensing operation or on the supply pipe to a manifold feeding equipment/dispensing operation. A single valve located at the entrance point to a building or cutoff room is also acceptable. 2.2.6.6 Safety/emergency shutoff valves or positive displacement pumps should be arranged for automatic and manual operation. In locations that are constantly attended and where leakage will be quickly discovered, manual operation is acceptable. Arrange both automatic and manual valve operation to shut down all flammable/combustible liquid flow in and to the area affected (i.e., shutdown valves at supply tank and at points of use). 2.2.6.7 Automatic operation of safety/emergency shutoff valves and/or positive displacement pumps should be accomplished by one of the following methods: a. Thermal actuation by use of heat detectors (e.g., HADs) located above the points of use (including potential leak points, such as pumps, that create a significant exposure), fusible link operated valves, or use of thermoplastic tubing for air supply to a pneumatic valve (loss of air supply will cause valve to close, thermoplastic tubing will melt when exposed to a fire). Fusible link operated valve placement should ensure it will be exposed to a fire caused by a flammable/combustible liquid release. If the valves placement limits its exposure to a potential fire, the valve should either be arranged to ensure its operation (e.g., in addition to link at valve, provide a second link over expected leak points with a cable attached to the valve
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handle which is arranged to close when the cable releases) or be replaced with a valve that can be remotely operated. b. Actuation by operation of a fire protection system such as automatic sprinklers and special protection systems (water spray, gaseous extinguishing system, etc.). Safety/emergency shutoff valves may be tied into pressure switches, waterflow alarms, or fire detection systems. Arrangements should be made to permit protection system alarm testing without unwanted production shutdown. c. Release of a dead-man type control or self-closing valve. These types of controls require constant attendance by the operator and will close automatically when the operator leaves. Provide self-closing valves at dispensing operations upstream of any flexible hose. d. Actuation by abnormal system conditions such as high/low pressure and excess flow. Use this arrangement to reduce a flammable/combustible liquid release before ignition when the expected fire or explosion exposure is excessive. Provide this type of actuation system in addition to a method listed above (ac). 2.2.6.8 Manual operation of safety/emergency shutoff valves and/or positive displacement pumps should be accomplished by providing one or more stop buttons or switches located within the flammable/combustible liquid operation area (arranged for easy access by the operators and at points of egress from the building or structure) and at accessible remote locations (e.g., control room, security station, etc.). 2.2.6.9 Provide check valves in piping arranged to feed tanks, receivers, or other vessels when: a) the liquid flow is in one direction only and b) the vessel can supply a leak in the feed pipe by reverse flow. Install the check valve as close to the vessel as possible. Check valves used on systems with materials that may impair their proper operation (e.g., paint, printing ink) should be physically checked regularly. 2.2.6.10 Provide hydraulic accumulators or safety relief valves on pipelines that can be valved off with liquid trapped between valves to prevent damage or overpressure from thermal expansion of the liquid. Pipe the relief valve discharge to a properly arranged collection point.
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a. Relief valves, rupture disks, pumps, tanks, and other portions of the piping system rated below the test pressure should be blanked off or removed. b. A pressure relief device set for the test pressure plus the lesser of 50 psig (3 bar g) or 10% of test pressure should be provided on the piping system. c. Provide a test pressure of 110% of the design pressure or a minimum of 3 psig (0.2 bar g). The system should be raised to the test pressure in steps to located large leaks at low pressures. d. Hold the test pressure for 30 minutes. e. After the test period, reduce the pressure to the design pressure and inspect for leaks using a solution of soap and water. f. All leaks should be repaired and the system retested until the test pressure can be held for the stated time period. 2.3 Flammable and Combustible Liquid Transfer Systems
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2.3.1.9 Pumps, located on open pads or in pump houses, without water spray protection should be spaced to limit exposure to important buildings as follows: a. High pressure (approx. >100 psig [7 bar g]) or high flow rate (approx. >100 gpm [23 cu m/h]) pumps should be spaced in accordance with Data Sheet 1-20, Protection Against Fire Exposure, (using Exposure B in Tables 2 through 7). b. Low pressure (approx. <100 psig [7 bar g]) or low flow rate (approx. <100 gpm [23 cu m/h]) pumps should be spaced in accordance with Data Sheet 1-20 (using Exposure C in Tables 2 through 7). 2.3.1.10 Pumps located on open pads protected with a water spray system should be spaced to limit exposure to important buildings as follows: a. High pressure or high flow rate pumps should be 50 ft (15 m) away from a building. Within 50 ft (15 m) the exposed wall should be at least one hour fire rated. b. Low pressure or low flow rate pumps should be 25 ft (8 m) away from a building. Within 25 ft (8 m) the exposed wall should be at least one hour fire rated. 2.3.1.11 Pumps located in pump houses protected with a water spray system should be spaced to limit the exposure to important buildings using Table 1, Construction for Flammable or Combustible Liquid Occupancies, (for high pressure or high flow rate pumps use the >1500 gal [6000 l] section; for low pressure or low flow rate pumps use the <1500 gal [6000 l] section). 2.3.1.12 Protect pumps located in pump houses or cutoff rooms in accordance with Sections 2.1.1 (Location and Construction), 2.1.3 (Ventilation), 2.1.4 (Ignition Sources), 2.1.5 (Employee Training and Maintenance), and 2.1.6 (Protection). Evaulate pump rooms or pump houses for a room explosion hazard based on the material being pumped.
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e. A pressure relief valve set at a slightly higher pressure than the regulator should be provided downstream of the regulator or on the tank. f. Provide the process supply line with a safety/emergency shutoff valve. g. Provide the tank fill line with a power operated control valve (e.g., solenoid, motor, air operated). h. Provide a liquid level control on the tank to prevent overflow. i. Vent lines for the storage tank (pressure relief line, directional valve vent line) should be provided with flame arresters for liquids with a flash point below 100F (38C).
2.3.3.5 The inert gas transfer system should be interlocked to operate as follows: a. During normal operation the safety/emergency shutoff valve should be open, the fill line control valve should be shut, and the directional valve on the gas supply line should be arranged to allow gas flow into the storage tank. b. During filling operations the safety/emergency shutoff valve should be closed, the fill line control valve should be open, and the directional valve on the gas supply line should be arranged to vent the tank pressure. c. During fire or leakage conditions the safety/emergency shutoff valve should be closed, the fill line control valve should be closed, and the directional valve on the gas supply line should be arranged to vent the tank pressure. Arrange the inert gas transfer system to prevent valve operation before confirmation of proper valve position (e.g., interlock valves on large systems electrically or provide clear procedures for manual valve operation on small systems). Arrange the control valves to operate automatically (i.e., interlock with safety/emergency shutoff valve) in the event of a fire or leakage.
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2.3.4.2 Tanks for hydraulic transfer systems should be constructed, installed, and tested in accordance with ASME or other recognized code for unfired pressure vessels. 2.3.4.3 Use a double tank arrangement (water tank and flammable liquid tank) to permit recovery and re-use of the water. A single tank arrangement is acceptable when other water recovery equipment is available (e.g., water treatment plant). (Fig. 9) 2.3.4.4 Arrange the hydraulic transfer system to operate on demand instead of continuous operation. 2.3.4.5 Supply the following minimum equipment for a double tank hydraulic transfer system (Fig. 9): a. Provide a positive displacement pump to deliver water to the flammable/combustible liquid storage tank. Place a foot valve on the suction supply line for the pump. b. Provide a check valve on the water delivery line and the flammable/combustible liquid tank fill line. c. A pressure relief valve set just above the system operating pressure should be provided downstream of the pump or on the tank. The pressure relief valve should be piped back to the water tank. d. A power operated control valve (e.g., solenoid, motor, air operated) should be provided on the process supply line and the flammable/combustible liquid tank fill line. e. Provide the water storage tank with a vent line. The vent line should be supplied with a flame arrester for liquids with a flash point below 100F (38C). f. A second water line with a control valve should be provided between the two tanks to permit water to return to the storage tank when the flammable/combustible liquid tank is being filled. g. Provide a liquid level control on the flammable/combustible liquid storage tank to prevent overflow. 2.3.4.6 Supply the following minimum equipment for a single tank hydraulic transfer system (Fig. 9): a. Provide an accessible manual control valve on the water supply line. b. Provide a pressure regulator on the water supply line. c. Provide a check valve on the tank fill line and the water delivery line (upstream of the two way valve). d. Provide a two-way, three port power operated valve on the water supply line (valve permits water delivery to tank or water removal from tank). e. A pressure relief valve set just above the operating pressure should be provided downstream of the regulator or on the tank. f. Provide a power operated control valve on the fill line and the process supply line. g. Provide a liquid level control on the tank to prevent overflow. 2.3.4.7 The double and single tank hydraulic transfer systems should be interlocked to operate as follows: a. During normal operation, the control valve on the process supply line is open and the control valve on the tank fill line is closed. For the single tank system, the two-way valve is arranged to permit water flow when needed. For the double tank system, the valve on the water return line is closed and the pump is arranged to operate when flow is needed. b. During flammable/combustible liquid tank filling operations, the control valve on the process supply line is closed and the control valve on the fill line is open. For the single tank system, the two-way valve on the water supply line allows water flow out of the tank. For the double tank system, the pump is off and the control valve on the water return line is open. c. During a fire or leak, the control valves on the process supply line and the fill line are closed. For the single tank system, the two-way valve is in the same position as described in part (b.). For the double tank system, the pump is off.
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Arrange the hydraulic transfer system to prevent valve or pump operation before confirmation of proper valve position (e.g., interlock the control valves and the pump). The valves and pump should operate automatically in the event of leakage or fire (i.e., interlock with safety/emergency shutoff valve at the point of liquid use).
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2.3.4.8 Arrange hydraulic transfer systems to prevent water flow into the process supply line. Double tank systems should use the same size tanks (limits water quantity). Single tank systems should use float operated control valves on the discharge lines (float will close when tank is full of water). 2.3.4.9 For flammable or combustible liquids that are lighter than water, the water supply line should be extended to the bottom of the liquid supply tank and the discharge and fill lines should be at the top of the liquid supply tank. For flammable or combustible liquids that are heavier than water, the water supply line should be at the top of the supply tank and the discharge and fill lines should extend to the bottom of the supply tank.
2.3.5.3 An automatic water spray special protection system, designed in accordance with Data Sheet 4-1N, Water Spray Fixed Systems, should be provided for loading/unloading stations when the station exposes high value plant facilities (i.e., inadequate separation) or if the station is vital to plant production. 2.3.5.4 Supply loading and unloading stations with either curbing, drainage, grading, or a combination to direct a potential liquid spill to a collection location that is accessible to fire fighting and liquid recovery operations but does not expose important buildings or facilities. 2.3.5.5 Supply loading and unloading stations with adequate control and safety/emergency shutoff valves to permit control of normal operations as well as isolation of the rail car or truck and plant piping systems in the event of a leak or fire. Provide safety/emergency shutoff valves on all bottom discharge lines of rail cars or trucks and on the plant side of flexible piping. Arrange the valves for automatic operation in the event of a fire as well as remote manual operation and protection from physical damage (e.g., internal tank valve with a shear fitting downstream). 2.3.5.6 Use top loading and unloading of rail cars and trucks when possible. Bottom loading and unloading is tolerable when: a. Space separation is provided as recommended. b. A liquid spill will not expose important buildings or facilities. c. Safety/emergency shutoff valves are provided on discharge lines of the rail car or truck. 2.3.5.7 Use positive displacement pumps for top unloading operations to prevent siphoning. Place the pump on a noncombustible platform above the liquid level and arrange it to shut down automatically or manually (from a remote location) in the event of a fire or leak. 2.3.5.8 Provide overflow protection for the rail car/truck or the storage tank. Arrange liquid level controls to automatically shut down filling operations when the tank is full. This control system may be used alone or in conjunction with meters, scales or manual observation.
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2.3.5.9 Use steel pipe and swing joints or metal type flexible hose when needed for connections to rail cars, tank trucks or barges. Metal reinforced rubber hose is acceptable if required by process conditions and if resistant to the materials being handled and rated for system pressure. 2.3.5.10 Provide the following at tank truck loading and unloading stations: a. Conduct all loading and unloading operations on level surfaces. b. Provide bonding and grounding in accordance with Data Sheet 5-8, Static Electricity. Connect bonding wires before opening tank domes. c. Set the trucks hand brake and block the wheels before connecting to fixed piping. d. Post warning signs indicating the tank truck is connected to the piping system. 2.3.5.11 Provide the following at rail car loading and unloading stations (Fig. 10): a. Conduct all loading and unloading operations on level tracks in a private siding on plant property or equivalent location with permanent piping to storage tanks. b. Provide stray current protection by bonding the fill pipe (or pipes) to at least one rail and to the rack structure (if metallic). In areas with excessive stray currents, provide all pipes entering the rack area with insulating flanges to electrically isolate the rack piping from the pipelines (Fig. 10).
Fig. 10. Railcar Loading/Unloading Station-Bonding Arrangement to Prevent Sparks Due to Stray Currents.
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c. Accurately align rail cars with loading/unloading connection points to avoid excessive stress on the connections. d. Protect rail cars against other moving railcars by providing derailers at least one car length away at the open end of the siding. The use of existing railroad switches is acceptable if they can be locked in the closed position. e. Set the brakes and block the wheels before connecting to the fixed piping system. f. Warning signs indicating the rail car is connected to the fixed piping system should be posted until the rail car is disconnected. 2.3.5.12 Vents on rail cars and trucks should be provided with flame arresters for liquids with flash points below 100F (38C). 2.3.5.13 Protect loading and unloading stations against uncontrolled ignition sources in accordance with Section 2.1.4. 2.3.5.14 Label all piping clearly to avoid intermixing materials. 2.3.5.15 All loading and unloading operations should be constantly attended. 2.3.5.16 Liquids that require heating for transfer purposes should be delivered in rail cars or trucks that are equipped with heating coils. Use the minimum steam pressure necessary to bring the liquid to a fluid state. Control the steam with a regulator set to the minimum pressure needed. Install a pressure relief valve downstream of the regulator set to a slightly higher pressure. 3.0 SUPPORT FOR RECOMMENDATIONS 3.1 Application of Recommendations
3.1.1 General
A flammable or combustible liquid is defined as any material that in its normal state is a liquid and will burn. The ability of a liquid to burn is generally tied to the existence of a flash point (closed cup or open cup). However, a flash point alone will not always indicate a liquid is capable of sustaining combustion. Some liquid solutions (e.g., 15% ethyl alcohol in water) may have a closed cup flash point but do not have a fire point (i.e., the liquid solution cannot produce enough flammable vapor to permit sustained combustionvapor mixture produced has a very low heat of combustion and slow heat release rate). The recommendations in this data sheet (general, piping system, transfer system) are not intended for liquids or liquid solutions that do not have a fire point (note: These liquid solutions may be labeled as a flammable or combustible liquid in accordance with state or federal regulations). Materials that are unstable or very reactive may not be adequately protected by this data sheet. Flammable liquids are easily ignited (vapors can be present at room temperature) and difficult to extinguish. Combustible liquids require heating for ignition and are easier to extinguish by cooling the liquid below its fire point with sprinkler discharge. Flammable and combustible liquids have a high heat of combustion and once ignited will produce a high heat release rate (i.e., fires will produce high temperatures in a short period of time). They are fluid and can spread rapidly when a leak or rupture involves a tank or piping system. Vapors from flammable and combustible liquids can form explosive mixtures with air. Some liquids are unstable or very reactive (e.g., burn when exposed to air without an ignition source, susceptible to spontaneous heating, react violently with other materials including water). These characteristics combine to create a significant fire and/or explosion hazard. The actual hazard associated with a particular process containing or using flammable or combustible liquids, in addition to the characteristics of the particular liquid, also depend on conditions such as: a. Quantity of liquid. b. The confinement of the liquid (open or closed containers, piping systems). c. The potential for leakage or overflow.
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d. Separation from important structures or buildings. e. Control of ignition sources. f. Available fire protection. Each process or occupancy should be evaluated separately to determine the actual exposure created by the flammable or combustible liquid.
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for creating a limited quantity of flammable vapor due either to low vaporization rates or limited liquid quantities.
is the weight of 1 gal of water (lb/gal) is the weight of 1 cu ft of air (lb/cu ft) is the specific gravity of the liquid (water=1) is the vapor density of the liquid, (air=1) is the liquids stoichiometric vapor concentration (vol. %)
To calculate the volume of a stoichiometric vapor-air mixture that can be produced from one liter of flammable/ combustible liquid, Vs (cu m/l), multiply the answer to the above equation by 0.00748 (note: this conversion factor has the following units[gal/l] [cu m/cu ft].) This calculation have been done for some common flammable liquids. The results are provided in Table 4. If a liquid being evaluated is not in the table, the above equation should be used to determine how much vapor will be created.
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Table 4. The volume of a stoichiometric vapor-air mixture that may be produced from either 1 gallon or 1 liter of some common flammable liquids. (Note: these values are based on complete vaporization of the liquid.) Material Acetone Benzene Ethyl Acetate Ethyl Alcohol Ethyl Ether Heptane Isopropyl Alcohol Methyl Alcohol Methyl Butyl Ketone Methyl Ethyl Ketone Pentane Toluene Vinyl Acetate Xylene Cst (% by Volume) 5.0 2.7 4.0 7.1 3.4 1.9 4.5 12.0 2.4 3.7 2.6 2.3 4.5 2.0 Vs (cu ft/gal) 890 1325 835 785 880 1170 945 675 1060 965 1025 1405 745 1355 Vs (cu m/l) 6.7 9.9 6.3 5.9 6.6 8.8 7.1 5.1 7.9 7.2 7.7 10.5 5.6 10.1
Loss history has also shown that a severe room explosion hazard can be created with liquids having flash points between 300F (149C) and 425F (218C) that are heated to their atmospheric boiling point and pressurized. These materials have the potential for creating an aerosol mist that can explode. Data Sheet 7-99, Heat Transfer by Organic and Synthetic Fluids, provides further discussion about these types of materials and mist explosions in general.
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Equipment containing liquids that can undergo violent chemical reactions should be evaluated using Data Sheet 7-49, Emergency Venting of Vessels. Equipment protection against a vapor-air/mist explosion hazard should always be considered since improperly designed/protected equipment will be significantly damaged by an internal vapor-air explosion. 4.0 APPENDIX 4.1 Definitions
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The flammable range for a vapor can be altered by changes in oxygen concentration, pressure changes or temperature changes. An increase in oxygen concentration or pressure will increase the upper flammable limit and have a minimal effect on the lower limit. An increase in temperature will increase the upper limit and reduce the lower limit. Overall, an increase in oxygen concentration, pressure or temperature will increase the hazard created by a flammable or combustible liquid by increasing its vapors flammable range.
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and c.) fluid properties. The following comparison, Table 5, of heats of combustion for flammable/combustible liquids and other combustible material illustrates one measure of fire hazard severity. The severity of a fire is also dependent on the heat release rate. A heat release rate generally depends on the heat of combustion, arrangement or geometry (e.g., exposed surface area), and combustion efficiency of the material. The heat release rate for a flammable/combustible liquid fire is greater than that of other combustibles because they have a high heat of combustion, favorable geometry, and a good combustion efficiency. The fluid properties of flammable/combustible liquids tend to create large surface areas when the liquids are released (e.g., unconfined liquid spill will spread over a large floor area; pressurized liquids can be released in the form of small drops or a mist). These properties also influence fire spread since a fire will expand over the full area of a spill or spray.
Table 5. Heat of Combustion for Representative Materials. Material Petroleum-Based Flammable/Combustible Liquids Pure Alcohols Distilled Whiskey (100 proof) Plastic Commodities Polystyrene Class III Commodities Heat of Combustion Btu/lb (kcal/kg) >20,000 (11,000) 13,000-14,000 (7,000-8,000) 5,000 (3,000) >10,000 (5,500) 17,000-18,000 (9,000-10,000) 6,000-9,000 (3,000-5,000)
4.2.1.1 Pool Fires Flammable or combustible liquids that are confined to open tanks or diked areas can create a pool fire. The confined liquid has a depth and controlled surface area. The heat release rate for this arrangement is limited by the exposed surface area of the liquid. The length of time the fire can burn is controlled by the liquid depth. This type of fire can release up to 10,000 Btu/min/sq ft (27,000 kcal/min/sq m) (assuming perfect combustion efficiency) of surface area. Approximately 1 gal (4 l) of liquid will be consumed each minute for each 12 sq ft (1 sq m) of surface area and approximately 1 in. (25 mm) of liquid will be consumed every seven minutes. 4.2.1.2 Unconfined Spill Fires. A flammable or combustible liquid released on a level surface without confinement will spread out over the surface and form a thin film. The area of the spill will depend on the amount of liquid released and the type of surface it is released on. A fire involving this spill can release 10,000 Btu/min/sq ft (27,000 kcal/min/sq m) of surface area. The fire duration depends on the quantity of liquid spilled. 4.2.1.3 Spray Fires. Flammable or combustible liquid spray fires result from leaks under pressure, as from hydraulic oil lines or liquid transfer piping. The spray (e.g., mist of small liquid droplets) is easily ignited, even at temperatures below the flash point of the liquid, in the same manner as fuel-oil discharge from a domestic oil burner. The liquid will burn nearly as fast as it is released producing heat release rates much greater than a pool or spill fire. A spray fire can produce approximately 120,000 Btu/gal (8,000 kcal/l). The duration of the fire depends on the fuel supply available and how quickly the fuel can be shut off.
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The principal effect of sprinkler water on flammable/combustible fires is one of cooling. Each gallon (liter) of water, heated to its boiling point and converted to steam, will absorb 8000 Btu (2000 kcal). For maximum cooling, vaporization should occur close to the burning surface. Droplet size and velocity are critical because the spray must penetrate a zone of flame and rising heat waves. Sprinkler discharge can extinguish a pool fire involving unheated liquids with a flash point over 200F (93C) by cooling the liquid below its fire point. Sprinkler protection may not extinguish a fire involving liquids with a flash point below 200F (93C) but they will hold temperatures at levels that will not cause major damage to buildings or equipment. (Fig. 11). Fires involving water soluble liquids or liquids heavier than water can be extinguished by sprinkler discharge (i.e., dilute liquid to a concentration where it no longer has a fire point or smother fire by water floating on surface of liquid). Sprinkler protection alone will not ensure control or extinguishment of a flammable or combustible liquid fire. The fires size must be limited by controlling a spills size (i.e., limit number of sprinklers that will operate by providing curbing to stop fuel spread) and controlling the fuel supply (i.e., limit water supply duration by ensuring fuel supply is cut off and drainage is provided to remove spilled fuel). Special protection systems (e.g., water spray, foam, gaseous, and dry chemical) are designed to extinguish a fire or provide localized cooling of equipment and buildings. Water spray protection systems deliver large amounts of water to a specific area that allows increased cooling (i.e., larger water droplets delivered at a higher velocity than available from ceiling sprinklers). These systems can extinguish fires in liquids with flash points above 150F (66C), some viscous liquids with lower flash points, water soluble liquids and liquids heavier than water. These systems are also suitable for providing exposure protection for equipment, building or facilities. Foam protection systems extinguish fires by blanketing the liquid and smothering the fire. The blanket persists for some time, reducing the likelihood of reflashing. The foam used must be compatible with the burning liquid. Foam may be delivered to a fire manually or automatically. Aqueous film forming foams (AFFF) may be delivered with open or closed head sprinkler systems. Gaseous protection systems extinguish flammable/combustible liquid fires by either reducing the oxygen content over the liquid or by interfering with the combustion reaction. The gaseous agent can be delivered by direct local application or by total flooding of the room or enclosure. No cleanup of the extinguishing agent is required after discharge. Dry chemical protection systems extinguish flammable/combustible liquid fires by coating the liquid surface and smothering the fire. The dry chemical agent can be delivered by direct local application or by total flooding of the room or enclosure.
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Explosion-protection systems are available that detect an incipient explosion and, by suppressing and/or venting action, prevent the full impact of the explosion from developing. They are adaptable to vapor-air explosion hazards in equipment and in small rooms. Boiling-liquid expanding-vapor explosions can be prevented by reducing heat input to the closed container or by bleeding off excess pressure from the container. Heat input rates can be reduced by insulation, by burying or mounding the vessel, or by automatic sprinklers or water spray. Excessive pressure can be prevented by atmospheric vent pipes, relief valves, bursting disks, or safety bungs.
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(Note: the above equation must only be used with metric units)
With: Av Pred Pstat V e d,f,g,h = = = = = = Vent Area, sq m Reduced Explosion Pressure, bar g Static Venting Pressure, bar g Vessel Volume, cu m 2.718 (base of natural logarithm) Constants as Defined in Table 6
To convert sq m to sq ft multiply by 10.76 sq ft/sq m To convert bar g to psig multiply by 14.5 psig/bar g To convert cu m to cu ft multiply by 35.31 sq ft/sq m The constants, d, f, g and h, used in Equation (1) depend on the type of gas/vapor present. The data and equation were developed based on four gases, methane, propane, coke gas and hydrogen. The composition limits for the coke gas were: 4555% 610% 2533% 4.6% 0.1% 23% Hydrogen Carbon Monoxide Methane Nitrogen Carbon Dioxide Unspecified Hydrocarbons
There are no available data to indicate whether the constants, determined for coke gas, vary significantly within these limits. The table below, Table 6, indicates the constants to be used for each gas:
Table 6. Explosion Venting Constants. Gas Methane Propane Coke Gas Hydrogen d 0.105 0.148 0.150 0.279 f 0.770 0.703 0.695 0.680 g 1.23 0.942 1.38 0.755 h -0.823 -0.671 -0.707 -0.393
Equation (1) is valid only for vessels with a length to diameter ratios of 5 or less and for the following ranges of Pred and vessel volume (V): 0.1 bar g Pstat 0.5 bar g Pstat+0.1 bar g Pred 2 bar g 1 cu m V 1000 cu m Pred is the maximum pressure that will be developed during the vented explosion and is the highest pressure that can be sustained by the equipment being protected. To prevent deformation of cylindrical equipment, Pred should be based on two-thirds of the equipments yield strength (stress). For rectangular or square equipment, the above criteria may be used, however, some additional bracing may be needed to prevent deformation. If deformation is acceptable, but not rupture of the equipment, then Pred should be based on two-thirds of the equipments ultimate strength (stress). (Note: the minimum listed ultimate strength for a material should always be used for this type of evaluation or design.) Determination of Pred based on the above criteria is best left to the equipment designer or a structural engineer. Lacking any data, use of twice the normal vessel design pressure (such as ASME rating) would be acceptable. Pstat is the set or relieving pressure of the deflagration vent. It should be at least 0.1 bar below the maximum desired pressure during venting, Pred.
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4.2.5.2 Vent Sizing for a Pr of 1.5 psig (0.1 bar g) or Less (Low Strength Equipment The design criteria provided in Data Sheet 1-44, Damage-limiting Construction, Tables 15, should be used to estimate the vent area needed for low strength equipment. The nomenclature listed in the data sheet represent the following: Pr = Maximum Vented Explosion Pressure, psf (kPa) (Note: this is equivalent to Pred for high strength equipment.) Pv = Vent Release Pressure, psf (kPa) Av = Vent Area, sq ft (sq m) As = Internal Surface Area, sq ft (sq m) Limitations listed in Data Sheet 1-44 should be strictly followed. The limitations for Tables 15 are discussed in section 3.2.8. Section 3.2.9 defines how to address providing vents at the ends of elongated enclosures. Pr is the maximum pressure that will be developed during the vented explosion and is the highest pressure that can be sustained by the equipment being protected. To prevent deformation of cylindrical equipment, Pr should be based on two-thirds of the equipments yield strength (stress). For rectangular or square equipment, the above criteria may be used, however, some additional bracing may be needed to prevent deformation. If deformation is acceptable, but not rupture of the equipment, then Pr should be based on two-thirds of the equipments ultimate strength (stress). (Note: the minimum listed ultimate strength for a material should always be used for this type of evaluation or design.) Determination of Pr based on the above criteria is best left to the equipment designer or a structural engineer. Lacking any data, use of twice the vessel design pressure would be acceptable. Pv is the set or relieving pressure of the deflagration vent. It should be at least 50 psf (2.4 kPa) below the maximum desired pressure during venting, Pr. Ideally Pv should be 20 psf (0.96 kPa) or less. Vent mass criteria listed in Data Sheet 1-44 are applicable for buildings and rooms only. The criteria listed in Section 4.2.5.4 should be used for equipment design. 4.2.5.3 Venting of Gases/Vapors Other Than Those Specified and Mists. Deflagration testing is used to compare the relative reactivity or hazard of various gases or vapors. When tested under similar conditions of turbulence, igniter strength and vessel size, the rate of pressure rise is a good measure of the ease of venting. Larger rates of pressure rise will require larger vent areas. A common measure of this factor is Kg (bar-m/sec) which is the rate of pressure rise normalized to vessel size. If vent size calculations for high strength equipment are necessary for gases or vapors other than the standard gases listed above, an acceptable choice would be to use Equation (1) with the venting constants for hydrogen (i.e., worst case, using Figure 1 and Table 5 in Data Sheet 1-44 would be the worst case for low strength equipment). A second alternative would be to refer to Data Sheet 1-44, Table 1, which lists many common gases and vapors. Based on the classification in Table 1, Equation (1) and Table 7 of this document, may be used with the venting constant for the comparable standard gas.
Table 7. Venting Constants for Other Vapors and Gases. Data Sheet 1-44 Table Number
3 4 5
For high or low strength equipment containing gases or vapors that are not listed in Data Sheet 1-44, tests should be conducted to determine the Kg for the new gas or vapor and compare it with Kg for any of the standard gases (conducted with the exact same vessel and conditions). Then either use Equation (1) and the venting constant for the comparable standard gas (high strength equipment) or the appropriate table in Data Sheet 1-44 for the comparable standard gas (low strength equipment). For additional details of classifying a particular gas/vapor refer to NFPA 68, Guideline for Venting of Deflagrations, Appendix A.
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All mist explosion hazards should be evaluated as follows: For high strength equipment use Equation (1) and the constants for propane in Table 6. For low strength equipment use Table 4 in Data Sheet 1-44. 4.2.5.4 Vent Mass and Location. The deflagration vent for low or high strength equipment should be of low mass per unit area. The vent should be less than 2.5 lb/sq ft (12.5 kg/sq m), to minimize inertia effects and delay in vent opening. The vent should open reliably and should not present a missile hazard. Vents should be centrally located for equipment with a single vent (i.e., use largest side of equipment and avoid small ends) or symmetrically arranged for multiple vents (i.e., provide several equally sized vents spaced evenly on equipment). 4.2.5.5 Vent Discharge Arrangement. Vents should be arranged to discharge to a safe location, preferably outdoors. For equipment located inside buildings or rooms, a vent pipe/duct may sometimes be used to direct discharge to a safe outdoor location. Vent pipes/ducts will, however, increase the vented explosive pressure experienced by the equipment due to: 1) the force needed to overcome the inertia of the air column in the pipe/duct, 2) the back-flow of combustion products created by escaping unburned gases igniting in the pipe/duct, and 3) friction losses due to the gas flow through the pipe/duct (minimal effect). This increase in pressure will require a similar increase in the strength of the equipment (Pred or Pr). Vent pipe/ducts on high strength equipment should be as short and straight as possible, preferably limit length to less than 10 ft (3 m) and avoid elbows or direction changes. Use Figure 12 to determine the increase in Pred to account for the effect of the vent pipe/duct. Failure to account for the vent pipe/duct effect may lead to equipment rupture during an explosion. Vent pipe/ducts should not be provided on low strength equipment. The vent pipe/duct effect will increase Pr beyond the definition of low strength equipment (i.e., Pr greater than 1.5 psig [0.1 bar g] so design for high strength equipment). Vent pipe/ducts with a length to diameter ratio (L/D) of 1 or less can be used on any equipment (high or low strength) without increasing Pr or Pred. Pipe/ducts with a diameter equal to or greater than its length will not generally produce an increase in the maximum pressure experienced by the equipment. 4.2.5.6 Effect of Turbulence. Equation (1) and the venting constants were based on quiescent mixtures in the test vessel. In some process equipment, the vapor space may be turbulent due to flow into and out of the vessel (e.g., gas injection into a reactor). If such conditions are likely, limited test data indicates Equation (1) and venting constants for hydrogen will provide acceptable venting for gases other than high Kg gases like hydrogen. Sizing vents for turbulent conditions of high Kg gases like hydrogen is not practical and other steps should be taken to protect vessels containing these materials (e.g., inerting the vapor space). The effect of ventilation induced turbulence within a piece of equipment may be disregarded when applying Equation (1) or Data Sheet 1-44. 4.2.5.7 Effect of High Initial Pressures. The vent area equations are based on gases at initial pressures around atmospheric. Usually they are considered valid up to 1.2 bar a (17.4 psia) initial pressures. Initial pressures beyond 1.2 bar a (17.4 psia) cannot be handled by Equation (1), of this document, or Data Sheet 1-44.
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*The 20 ft (6 m) upper limit on length is a FME&R standard. (Reprinted from NFPA 68, Guide for Venting of Deflagrations1988 edition, 1988)
Fig. 12. Maximum Pressure Developed During Venting of Gases, With and Without Vent Ducts.
4.3 Miscellaneous
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1. Ordinary heat-treated soda-lime glass is suitable only for operations at normal atmospheric pressures and temperatures. 2. Specially heat-treated soda-lime glass is suitable for pressures of approximately 150 to 300 psig (10-20 bar g) and temperatures up to 400F (204C). 3. Annealed borosilicate glass is used at temperatures and pressures similar to those for heat-treated soda-lime. 4. Tempered borosilicate glass is used for higher temperatures than the annealed glass, but is is more subject to chemical deterioration. 5. High-silica glass is suitable for operations at high temperatures but only at low pressures. 4.3.1.3 Sight Glass Design. Glasses are usually circular. Older designs use a single glass mounted between two bolted flanges with gaskets to separate the glass from metal surfaces. Newer FMRC-Approved designs are available. One incorporates two tempered borosilicate glass pressures disks and an inside shield disk to protect against chemical deterioration, all sealed into one lens. The lens is bonded in a special holder to reduce lens pressures and stresses. Another FMRC-Approved design incorporates two tempered borosilicate glass pressure disks, with or without an inside shield disk, bonded into a lens assembly. A soft gasket fits around the glass circumferentially. A set screw and metal-compression-ring arrangement presses against the gasket, which in turn holds the glass in place by circumferential forces. This is intended to minimize tensile stress in the glass.