PrefaceAbout the Author1 Introduction 1.1 Fire, Explosions, and Environmental Pollution 1.2 Historical Background 1.3 Legal Influences 1.4 Hazards and Their Prevention 1.5 Risk Management and Insurance 1.6 Senior Management Responsibility and Accountability2 Overview of Oil and Gas Facilities 2.1 Introduction 2.2 Exploration 2.3 Production 2.4 Enhanced Oil Recovery 2.5 Transportation 2.6 Refining 2.7 Typical Refinery Process Flow 2.8 Marketing3 Philosophy of Protection Principles 3.1 Introduction 3.2 Legal Obligations 3.3 Insurance Recommendations 3.4 Company and Industry Standards 3.5 Worst Case Condition 3.6 Independent Layers of Protection 3.7 Design Principles 3.8 Accountability and Auditability4 Physical Properties of Hydrocarbons 4.1 Introduction 4.2 General Description of Hydrocarbons 4.3 Characteristics of Hydrocarbons 4.4 Flash Point 4.5 Autoignition Temperature 4.6 Vapor Density Ratio 4.7 Vapor Pressure 4.8 Specific Gravity 4.9 Flammable 4.10 Combustible 4.11 Heat of Combustion 4.12 Some Common Hydrocarbons5 Characteristics of Hydrocarbon Releases, Fires, and Explosions 5.1 Introduction 5.2 Hydrocarbon Releases 5.3 Gaseous Releases 5.4 Mists or Spray Releases 5.5 Liquid Releases 5.6 Nature and Chemistry of Hydrocarbon Combustion 5.7 Hydrocarbon Fires 5.8 Deliberate Terrorist Explosions 5.9 Semi-Confined Explosion Overpressures 5.10 Vapor Cloud Overpressures 5.11 Boiling Liquid Expanding Vapor Explosions 5.12 Smoke and Combustion Gases 5.13 Mathematical Consequence Modeling 5.14 Methods of Extinguishing Flames 5.15 Incident Scenario Development 5.16 Terminology of Hydrocarbon Explosions and Fires6 Historical Survey of Fire and Explosions in the Hydrocarbon Industries 6.1 Introduction 6.2 Lack of Industry Incident Database and Analysis 6.3 Insurance Industry Perspective 6.4 Process Industry Perspective 6.5 Major Incidents Affect Process Industry Safety Management 6.6 Incident Data 6.7 Summary7 Risk Analysis 7.1 Introduction 7.2 Risk Identification and Evaluation 7.3 Specialized Supplemental Studies 7.4 Risk Acceptance Criteria 7.5 Relevant and Accurate Data Resources 7.6 Insurance Risk Evaluations8 Segregation, Separation, and Arrangement 8.1 Introduction 8.2 Segregation 8.3 Separation 8.4 Manned Facilities and Locations 8.5 Process Units 8.6 Storage Facilities – Tanks 8.7 Flares and Burn Pits 8.8 Critical Utilities and Support Systems 8.9 Arrangement 8.10 Plant Roads – Truck Routes, Crane Access, and Emergency Response9 Grading, Containment, and Drainage Systems 9.1 Introduction 9.2 Drainage Systems 9.3 Process and Area Drainage 9.4 Surface Drainage 9.5 Open Channels and Trenches 9.6 Spill Containment10 Process Controls 10.1 Introduction 10.2 Human Observation 10.3 Electronic Process Control 10.4 Instrumentation, Automation, and Alarm Management 10.5 System Reliability 10.6 Transfer and Storage Controls 10.7 Burner Management Systems11 Emergency Shutdown 11.1 Introduction 11.2 Definition and Objective 11.3 Design Philosophy 11.4 Activation Mechanism 11.5 Levels of Shutdown 11.6 Reliability and Fail Safe Logic 11.7 Esd/Dcs Interfaces 11.8 Activation Points 11.9 Activation Hardware Features 11.10 Isolation Valve Requirements 11.11 Emergency Isolation Valves 11.12 Subsea Isolation Valves 11.13 Protection Requirements 11.14 System Interactions12 Depressurization, Blowdown, and Venting 12.1 Introduction 12.2 Objective of Depressuring 12.3 Blowdown 12.4 Venting 12.5 Flares and Burn Pits13 Overpressure and Thermal Relief 13.1 Introduction 13.2 Causes of Overpressure 13.3 Pressure Relief Valves 13.4 Thermal Relief 13.5 Solar Heat 13.6 Pressure Relief Device Locations14 Control of Ignition Sources 14.1 Introduction 14.2 Open Flames, Hot Work, Cutting, and Welding 14.3 Electrical Arrangements 14.4 Electrical Area Classification 14.5 Electrical Area Classification Divisions and Groups 14.6 Surface Temperature Limits 14.7 Classified Locations and Release Sources 14.8 Protection Measures 14.9 Smoking 14.10 Static 14.11 Lightning 14.12 Internal Combustion Engines 14.13 Hot Surface Ignition 14.14 Pyrophoric Materials 14.15 Spark Arrestors 14.16 Hand Tools 14.17 Mobile Telephones, Laptops, and Portable Electronic Field Devices15 Elimination of Process Releases 15.1 Introduction 15.2 Inventory Reduction 15.3 Vents and Relief Valves 15.4 Sample Points 15.5 Drainage Systems 15.6 Storage Facilities 15.7 Pump Seals 15.8 Vibration Stress Failure of Piping 15.9 Rotating Equipment16 Fire and Explosion-Resistant Systems 16.1 Introduction 16.2 Explosions 16.3 Definition of Explosion Potentials 16.4 Explosion Protection Design Arrangements 16.5 Vapor Dispersion Enhancements 16.6 Damage-Limiting Construction 16.7 Fireproofing 16.8 Radiation Shields 16.9 Water Cooling Sprays 16.10 Vapor Dispersion Water Sprays 16.11 Locations Requiring Consideration of Fire-Resistant Measures 16.12 Flame Resistance 16.13 Fire Dampers 16.14 Smoke Dampers 16.15 Flame and Spark Arrestors 16.16 Piping Detonation Arrestors17 Fire and Gas Detection and Alarm Systems 17.1 Introduction 17.2 Fire and Smoke Detection Methods 17.3 Smoke Detectors 17.4 Thermal or Heat Detectors 17.5 Gas Detectors 17.6 Application 17.7 Catalytic Point Gas Detector 17.8 Infra-Red (IR) Beam Gas Detector 17.9 Ultrasonic Area Gas Detector 17.10 Alarm Setting 17.11 Calibration 17.12 Hazardous Area Classification 17.13 Fire and Gas Detection Control Panels 17.14 Graphic Annunciation 17.15 Power Supplies 17.16 Emergency Backup Power 17.17 Time Delay 17.18 Voting Logic 17.19 Cross Zoning 17.20 Executive Action 17.21 Circuit Supervision 17.22 Vibration Avoidance18 Evacuation 18.1 Introduction 18.2 Emergency Response Plan 18.3 Alarms and Notification 18.4 Evacuation Routes 18.5 Emergency Doors, Stairs, Exits, and Escape Hatches 18.6 Marking and Identification 18.7 Shelter-in-Place 18.8 Offshore Evacuation19 Methods of Fire Suppression 19.1 Introduction 19.2 Portable Fire Extinguishers 19.3 Water Suppression Systems 19.4 Water Supplies 19.5 Fire Pumps 19.6 Fire Pump Standards and Tests 19.7 Firewater Distribution Systems 19.8 Firewater Control and Isolation Valves 19.9 Sprinkler Systems 19.10 Water Deluge Systems 19.11 Water Spray Systems 19.12 Water Flooding 19.13 Steam Smothering 19.14 Water Curtains 19.15 Blow Out Water Injection Systems 19.16 Hydrants, Monitors, and Hose Reels 19.17 Nozzles 19.18 Foam Suppression Systems 19.19 Manual Firefighting Utilization 19.20 Gaseous Systems 19.21 Chemical Systems 19.22 Dual Agent Systems20 Special Locations, Facilities, and Equipment 20.1 Introduction 20.2 Arctic Environments 20.3 Desert Arid Environments 20.4 Tropical Environments 20.5 Earthquake Zones 20.6 Offshore Facilities 20.7 Pipelines 20.8 Exploration Wellheads (Onshore and Offshore) 20.9 Loading Facilities 20.10 Electrical Equipment and Communications Rooms 20.11 Oil Filled Transformers 20.12 Battery Rooms 20.13 Enclosed Turbines or Gas Compressor Packages 20.14 Emergency Generators 20.15 Heat Transfer Systems 20.16 Cooling Towers 20.17 Hydrocarbon Testing Laboratories (Including Oil or Water Testing and Darkrooms) 20.18 Warehouses 20.19 Cafeterias and Kitchens21 Human Factors and Ergonomic Considerations 21.1 Introduction 21.2 Human Attitude 21.3 Control Room Consoles 21.4 Field Devices 21.5 Instructions, Markings, and Identification 21.6 Colors and Identification 21.7 Noise Control 21.8 Panic 21.9 Security 21.10 Accommodation of Religious PracticesAppendicesAppendix A: Testing Firewater Systems A.1 Testing of Firewater Pumping Systems A.2 Testing of Firewater Distribution Systems A.3 Testing of Sprinkler and Deluge Systems A.4 Testing of Foam Fire Suppression Systems A.5 Testing of Firewater Hose Reels and Monitors A.6 Fire Protection Hydrostatic Testing RequirementsAppendix B: Reference Data B.1 FIre Resistance Testing Standards B.2 Explosion and Fire Resistance Ratings B.3 National Electrical Manufacturers Association (Nema) Classifications B.4 Hydraulic Data B.5 Selected Conversion FactorsAcronym ListGlossaryIndex