Value Engineering for Gasoline Tanks Fire Fighting System

1. KING FAHAD UNIVERSITY OF PEROLEUM AND MINERALSDEPARTMENT OF CONSTRUCTION AND MANAGEMENTCEM 512 VALUE ENGINEERINGTERM PROJECTFIRE FIGHTING SYSTEM FOR GASOLINE FLOATING ROOF TANKS AT DH BULK PLANT PREPEARED BY: MOHAMMED A. AL-JUMAIA PRESENTED TO: DR. SADI ASSAF

2. PRESENTATION OUTLINE • INTRODUCTION • PROJECT DESCRIPTION • WHAT IS FLOATING ROOF TANK • DATA AND EXPERINCE FROM ACTUAL TANK FIRES AND IMPORTANCE OF FIRE FIHTING SYSTEM • OBJECTIVE • VALUE ENGINEERING JOB PLAN • INFORMATION PHASE • CREATIVE PHASE • JUDICIAL PHASE • DEVELOPMENT PHASE • PRESENTATION PHASE • IMPLEMENTATION PHASE • CONCLUSION • OPEN DISCUSSION

3. INTRODUCTION PROJECT DESCRIPTION • Additional Capacity Requirements Project • Upgrade Objective • To meet the local market demand for gasoline up to 2015 • Scope of work • Two 125,000 bbl floating roof tanks (41m dia.) • To provide tank dike, MCC room, OWS, roads and lighting at the new tank farm area • To construct and install 12” run down pipeline loop from tank farm to loading area. • To construct new loading rack consist of 3 loading skids, canopy, OWS, fire fighting system and other infrastructure facilities.

5. INTRODUCTION What is the floating roof tank It is an atmospheric tank( An internal pressure that does not exceed the weight of the tank roof) used to storage fuel and organic liquid. • Two types • External (open-top) floating roof tanks specified for: 1) Crude oil (stabilized); 2) Low-flash liquids; 3) Liquid that is stored at a temperature within 8°C of its flash point, or higher; 4) Liquids having a Reid vapor pressure from 14 kPa absolute (2 psia) to 76 kPa absolute (11 psia).

9. INTRODUCTION • Internal floating roof tanks specified for : 1) Services listed for external floating when small storage volumes are required and the use of internal floating roof tanks is more economical than external floating roof tanks. 2) Services when product contamination from weather elements is to be minimized. 3) Services where existing fixed roof tanks are to be converted to internal floating roof tanks to minimize evaporation losses and/or emissions.

11. INTRODUCTN DATA AND EXPERINCE FROM ACTUAL TANK FIRES AND IMPORTANCE OF FIRE FIHTING SYSTEM • Large-scale tank fires are very rare but they present a huge challenge to fire fighters, oil companies and the environment. • There only two alternatives for combating such a fire, either to let it burn out and thereby self-extinguish or, alternatively, to actively extinguish the fire, using fire fighting systems. • As the burn our procedure will result in a fire that is likely to last several days, complete loss of the stored product, environmental problem, large cooling operation to protect fire spread to adjacent tanks, this is often not an acceptable alternative.

12. INTRODUCTN • Historically the chance of successful fire control and extinguishment have been low, especially for large tanks. • Before 2001 there had been no successful extinguishment for tanks larger than 45 m in diameter. • Tanks exceeding 100 m exist and there are some debate concerning whether it would be possible to extinguish in the largest tanks at all.

13. Tank Fire Fighting Methods Use Foam systems Use FW loop around tanks (hydrant, monitor) Use Halon External support means (Fire Protection Department)

14. OBJECTIVE • To protect the new gasoline floating roof tanks. • To evaluate the designed fire fighting system for the new EFRT. • To meet Saudi ARAMCO standard and requirements. • To reduce the cost and improve the system.

15. Information Phase • The design was approved and the contract awarded. • Site preparation completed along with tank ring beams including the tank External CP system • SAPMT assigned one engineer from each discipline to review the drawings and the specification. • They assigned me to evaluate the ME/Civil drawings • I reviewed the drawings and generated and developed three proposals for implementation • Replace the fixed foam system with semi-foam system. (implemented) • Delete the water drainage system and skimmer tank and replace it with sump pit and vacuum truck provision.( implemented) • Lower the loading rack canopy to reduce the cost and improved the fire fighting system.( approved but not implemented)

16. What is the problem with the original design • The results of my investigation shows that: • The existing system is not reliable. • Evaluation of condition and performance of the existing foam generation skid was not conducted during design stage (FPD test documents shows low performance) • The system operated manually and calculation shows many mistake. • Foam flow rate low which result in long traveling time. • The cost/worth show potential cost reduction proposal.

17. The original design for the fire protection system for the new tanks • Install a fixed foam system to protect the new gasoline floating roof tanks. • In order to accomplish this job • Install U/G RTR piping system • Tie-in to the existing U/G CS cement line to supply foam to the tanks from the existing foam skid • Install cement line CS with piping ring and chamber

21. Performance Criteria • Meeting SAES-B-18, Air Foam System for Storage Tanks and applicable NFPA standard. • Tanks 38 m (125 ft) and over in diameter shall have multiple fixed foam chambers and deflectors located at intervals not to exceed 24.4 m (80 ft), equally spaced around entire tank shell. • Solution flow rate shall be 470 gpm.

22. Present Function Identification What does it now do? Verb Noun Fight Fire Protect Tank Protect Facilities Protect People What must it do? Verb Noun Fight Fire Protect Tank Protect Facilities

23. Function Worksheet

24. CREATIVE PHASE • The followings ideas were generated during this phase:

26. JUDICIAL PHASE Feasibility Ranking Replacement cost Probability of implementation Potential cost Cost to develop Total Rank Time to implement

27. JUDICIAL PHASE Idea Comparison

30. Development Phase • The two EFRT can be protected by utilizing the proposal of the Sami-fixed foam system. • By this proposal • The cost will be reduced (initial and O&M) • The Performance will be improved • The proposed system meet SA requirements and standard. • The implementation time will be improved and materials delivery date were advanced. • The accurate cost estimate prepared with detailed material take off, I prepared the calculation, sized the piping and revised the drawings.

31. 37,395

32. Development Phase Life Cycle Cost Analysis Initial Saving 236, 564 SR (86%) Life cycle cost saving 569, 761 SR (85%)

33. Presentation Phase • Meeting was conducted with SAPMT Sr. PE and PE to discuss the issue and the execution plan. • Meeting with • FPD • EPD • CSD • Proponent DH (ECRDD) • Letter for approval were prepared and approved.

34. Implementation Phase • The proposal approved by SAPMT management. • No time impact on schedule • Positive cost impact on the project • Change ordered were issued negotiated and approved to let contractor proceed with changes.

35. Conclusion • The proposal has some limitation • Fire station shall be not far than 15 minutes from the lateral terminal connection. • Accessibility is essential criteria. • FW monitor or hydrant shall be close to the lateral terminal not more than 60m and not less than 15m • Geotechdome is under review due to elimination of foam system requirement and recovery system which improved product storage.

36. Thanks Q&A