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Petroleum Development Oman L.L.C.

Document Title: Operational Integrity Testing of Fixed


Firefighting Systems

Document ID PR-1147

Document Type Procedure

Security Unrestricted

Discipline Engineering and Operations

Owner UOP – Functional Production Manager

Issue Date August 2011

Revision 3.0
Revision: 3.0
Petroleum Development Oman LLC Effective: Aug-11

This page was intentionally left blank

This document is the property of Petroleum Development Oman, LLC. Neither the whole nor any part
of this document may be disclosed to others or reproduced, stored in a retrieval system, or
transmitted in any form by any means (electronic, mechanical, reprographic recording or otherwise)
without prior written consent of the owner.

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i Document Authorisation
Authorised For Issue – August 2011

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ii Revision History
The following is a brief summary of the 4 most recent revisions to this document. Details of all
revisions prior to these are held on file by the issuing department.

Revision No. Date Author Scope / Remarks


3.0 Aug-11 Robin Norman UOP6 Reviewed and Revalidated
2.0 Dec-07 Robin Norman UOP6 Reformat, Review and Revision
Title amended.
Sep-01 UOP1 Reviewed and Revalidated
1.0 Oct-98 UOP1 New Procedure.

iii Related Business Processes


Code Business Process (EPBM 4.0)
EP.71.02 Operate Wells and Facilities

iv Related Corporate Management Frame Work (CMF)


Documents
The related CMF Documents can be retrieved from the CMF Business Control Portal.

Refer to Appendix 2

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TABLE OF CONTENTS
1 Introduction........................................................................................................................... 6
1.2 Purpose........................................................................................................................... 6
1.3 Distribution / Target Audience.......................................................................................... 6
1.4 Changes to the Document............................................................................................... 6
1.5 Step-out Approval............................................................................................................ 6
2 Roles and Responsibilities.................................................................................................... 7
3 Operations Integrity Testing of Fixed Firefighting Systems Procedures................................8
3.1 Scope.............................................................................................................................. 8
3.2 Permit to Work and Safety System Overrides................................................................8
3.3 Firewater Ring Mains and Firewater Pumps...................................................................8
3.4 Firewater Deluge Systems............................................................................................10
3.5 Foam Systems.............................................................................................................. 12
3.6 Sprinkler Systems......................................................................................................... 15
3.7 Fire Suppressant Delivery Systems..............................................................................16
4 Testing, Maintenance and Fault / Defect Reporting............................................................18
4.1 Operational Testing........................................................................................................ 18
4.2 1st Line Maintenance..................................................................................................... 18
4.3 Fault / Defect Reporting................................................................................................19
Appendix 1 – Abbreviations........................................................................................................ 20
Appendix 2 – Reference Material...............................................................................................21
Appendix 3 - User Feedback Page............................................................................................ 22
Addendum – Changes to the Document at Revision 3.0...........................................................23

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1 Introduction
1.1 Background
Fixed Firefighting systems are provided at the majority of facilities in the North, South
Gas Directorates to provide the capability to fight major hydrocarbon fires. The systems
are fully automatic or require some manual intervention to be activated. It is the
responsibility of all personnel on the sites to ensure that these systems are maintained
and tested regularly so that they are always available.
Typically sites shall be provided with one or more (dependant on type of operation) of
the following:
 Fixed firewater system comprising of dedicated pumps, ring main and hydrants
 Fixed water deluge system (selected vessels and areas)
 Foam delivery systems (including tank injection)
 Sprinkler systems for offices, warehouses, stores etc.
 Fire suppressant delivery system for containerised equipment such as
switchgear, compressors, generators etc.
Regular periodic testing of the systems shall be undertaken by Operations personnel at
the site and any defects or irregularities recorded in the station log and reported to
Production Coordinator for action and rectification.

1.1 Purpose
This procedure details at high level the requirements for testing and 1 st line
maintenance for all fixed firefighting systems located at the various locations in PDO.
Where required more detailed procedures shall be provided specific to the location.

1.2 Distribution / Target Audience


This procedure shall be referenced by all Operations and Maintenance personnel in
connection with integrity testing of fixed firefighting equipment.

1.3 Changes to the Document


Responsibility for the upkeep of the Document shall be with the Functional Production
Manager (UOP), the Owner. Changes to this document shall be authorised by the
Owner.
Users of the Document who identify inaccuracy or ambiguity can notify the Custodian
or his / her delegate and request changes be initiated. The Requests shall be forwarded
to the Custodian using the ‘User Feedback Page’ provided in this Document.
The Document Custodian on behalf of the Document Owner shall ensure review and
re-verification of this procedure every 3 years.

1.4 Step-out Approval


This procedure is mandatory and shall be complied with at all times. Should
compliance with the procedure be considered inappropriate or the intended activity
cannot be effectively completed or safely performed, then step out authorisation and
approval must be obtained in accordance with PR-1001e – Operations Procedure
Temporary Variance, prior to any changes or activities associated with the procedure
being carried out.

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2 Roles and Responsibilities


Production  Responsible for ensuring that Fixed Firefighting
Coordinator Systems are tested and maintained in accordance
with this procedure
 Audits reports and records of inspections and
tests
Production  Responsible for overseeing the Fixed Firefighting
Supervisor System test
 Witnessing and verifying test results
Production  Undertaking Fixed Firefighting System testing in
Operator accordance with this procedure and local specific
procedures
 Undertaking 1st Line Maintenance in accordance with
this procedure or maintenance schedules
 Raise Z1 Notification when faults or defects are
identified
Maintenance  Assisting and performing 1st Line and Corrective
Technician maintenance in accordance with this procedure or
maintenance schedules
 Raise Z1 Notification when faults or defects are
identified

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3 Operations Integrity Testing of Fixed Firefighting Systems


Procedures

3.1 Scope
The procedure covers Fixed Firefighting Systems irrespective of the location. The level
has been kept suitably high level so that the procedures can be applicable to all or
most location within PDO.
Fixed Firefighting Systems are defined as stated in Section 1.1 of the procedure but
can be generally assumed to be fixtures that are not easily moveable.
Included where applicable in each procedure shall be references to maintenance tasks
that can be undertaken by operations personnel with any specialist training. Reference
should be made to PR-1100 - Operator Routine Functions for more details on this
subject.

3.2 Permit to Work and Safety System Overrides

3.2.1 Permit to Work (PTW)


PTW certificate may be required during integrity testing of fixed firefighting systems
dependant on the type of testing being undertaken.
For example:
 A PTW will not be required for; testing of the jockey pump for ‘auto’ start by
relieving pressure in the firewater system and monitoring auto start / stop
pressure; or testing the ‘auto’ start of the firewater pump while set to automatic
mode; provided the work is carried out by operations.
 A PTW will be required when performance testing the firewater pump; dry
testing a deluge system with firewater supply isolated; or checking the
condition of the frangible bulbs on a sprinkler head.

3.2.2 Temporary Overrides on Fixed Firefighting Systems


Integrity testing of fixed firefighting systems may require that automatic detection and
initiation systems to be overridden for the duration of the work. Overriding will be
carried out in accordance with PR-1001c - Temporary Overriding of Safeguarding
Systems and under the PTW system.
The use of overrides must be recorded in the Station Override Log when applied and
removed. Overrides will only be applied by authorised personnel under strict control
and remain in place while the station is manned.

3.3 Firewater Ring Mains and Firewater Pumps

3.3.1 General
Firewater ring main systems will be provided on most sites where continuous fire
protection is required. Generally the systems are supplied from a dedicated water
supply and are maintained pressurised via a jockey pumps.

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Larger diesel driven or electrically driven firewater pump(s) shall be provided for the
delivery of firewater to the system ring main should an emergency occurs that requires
large volumes of water to be supplied under pressure. The firewater pump(s) are
automatically started on initiation of a confirmed fire signal from the F&G Logic or low
pressure in the ring main caused by opening of fire hydrants.

3.3.2 Operational Integrity Testing

1. Check the operation of the jockey (pressurising) pump. Ensure the pump
operates between the high and low pressure settings to maintain firewater ring
main pressure.
2. Inspect firewater ring main above ground for signs of corrosion or damage.
3. Inspect firewater hydrants for damage and corrosion. Ensure that the seals are
in good condition and that covers are fitted to prevent the ingress of sand.
Lightly grease the rubber seals to maintain flexibility.
4. Check the operation of all fire fighting monitors 1. Lubricate and grease where
required.
5. Check operation of main isolation and X-connection valves. Ensure valves are

1
Automatic oscillating fire monitors should have a maintenance routine applied in addition to
that required by this procedure.
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not seized or stiff. Grease spindles and gearing where applicable.


6. Select the TEST mode at the Firewater Pump Panel 2.
7. Initiate a start of the Firewater Pump(s) by any of the automatic start
parameters such as:
 Low firewater ring main pressure
 MAC
 Remote firewater pump start location
 Remotely from the F&G Panel in the CCR
8. Check operation of the minimum flow loop
9. Check firewater ring main and hydrants for leaks. Ensure that there are no
excessive leaks on the valves gland.
Record pressure and flow and record.
10. Stop Firewater Pump(s) and return system logic to normal standby position.
11. Sign off test, record readings if required and report all defective equipment /
leaks.

3.4 Firewater Deluge Systems

3.4.1 General
Generally deluge systems are provided to protect vessels and tanks from radiant heat
caused by surrounding fires. Firewater is distributed across the protected area using
nozzles which are fixed to provide a drenching pattern. Normally the systems are
maintained dry and firewater is allowed to enter the system by the operation of a ‘clack
valve’. The clack valve can be operated from fusible loops or from the F&G logic.
On installations where a fixed firewater system is not available then the deluge
systems may be supplied from dedicated pressurised water tanks. The duration of the
system is then limited to the amount of water stored in the tank and the availability of
back-up supplies.

3.4.2 Operational Integrity Testing


1. Is the Operational Integrity Test to be performed using a ‘wet’ or ‘dry’ system?
i.e. is water to be allowed through a normally dry system. If the test is to be
‘dry’ reference steps 2 through 5 below. For a ‘wet’ test proceed to step 6.
2. Apply the required ‘Maintenance Overrides’ or ‘Defeats’ on the system to
prevent the introduction of firewater / water to the system discharge pipework.
3. Isolate the main firewater / water isolation valve (upstream of the clack valve).
4. Activate the Deluge release for the respective area under test from the fusible
loop, local release point or F&G logic. Ensure that all alarm and indication is
activated and is in the correct sequence.
NOTE: The Overrides will prevent executive actions such as firewater pump
start and SDV shut in from occurring if these are part of the operation logic for
the system.
5. On successful completion of the test reset the system and remove the

2
The Firewater Pump Panel is set to TEST to protect the pump during the test running. Normal
logic is for the all safety shutdowns are overridden in a fire situation. The pump will run to
destruct. “Stressed engine condition” safeguards are not permitted on firewater pumps e.g.
cooling water monitoring, etc.
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Overrides. Ensure firewater / water isolation is open.

6. Inspect the area where the test is to initiated and ensure that exposed
equipment such as motors and control panels are protected from water
ingress.
7. Before initiating a ‘wet’ test all personnel in the area shall be informed that a
test is about to take place.
8. Activate the respective deluge system from the local or remote release points.
The release may be from the fusible loop, local release point of via the F&G
logic.

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9. Check that all executive actions (unless overridden) and alarms and indication
are correct.
NOTE: Executive actions associated with a deluge release can include remote
starting of the firewater pump(s) and a station ESD. If any associated action is
not required then the appropriate override shall be put in place.
Check deluge supply pressure are correct for the system.
Check the distribution of the deluge and that all nozzles are operating correctly.
Record any defects.
10. On successful completion of the test reset the system and remove any
overrides which have been set.
If the system pipework is normally dry it should be blown through with dry air to
remove any free water.
11. Sign off test, record readings and report all defective equipment / leaks.

3.5 Foam Systems

3.5.1 General
Foam systems are provided where free surface liquid fires could occur or as a means
of suppressing fires in the roof space floating roof storage tanks.
Foam can be generated through foam monitors or from dedicated foam generation
skids (as used for MAF storage tanks). The chemical foam compound is induced into
the firewater stream through an inductor and is mixed to produce foam at the nozzle or
the injection point.
Foam is stored either in containers alongside the monitor with the inductor hose
connected to the monitor and the tank or in the case of larger fixed systems in a foam
concentrate tank attached to the inductors of the skid.
Initiations of the monitors are normally manual and for the fixed skid installations from
a fusible plug loop and automatic clack valve.

3.5.2 Operational Integrity Testing


1. Is the Operational Integrity Test to be performed using a Foam release?
If a foam release is to be used then a decision shall be made by the Production
Supervisor as to whether the release shall to the protected area or not. It may
be advisable for operational reasons to direct the foam to a vacant area in
which case if provision in the pipework (fixed system) is not made a temporary
break in the pipework may be required.
If the test is to be ‘without foam’ reference steps 2 through 6 below. For a
‘foam’ test proceed to step 7.
2. Apply the required ‘Maintenance Overrides’ or ‘Defeats’ on the system to
prevent the unplanned shutdowns.

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3. Isolate the foam concentrate supply and ensure the foam concentrate supply
pump if provided is electrically isolated or set to Local to prevent starting.
4. Activate the Foam System for the respective area under test from the fusible
loop, local release point or F&G logic.
Ensure that all alarm and indication is activated and is in the correct sequence.
NOTE: The Overrides will prevent executive actions such as ESD and / or
SDV shut in from occurring if these are part of the operation logic for the
system.
5. On successful completion of the test reset the system and remove the
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Overrides. Ensure foam concentrate isolation valves are Opened and the foam
concentrate supply pump is electrically de-isolated or rest to AUTO.
6. Take samples of the foam concentrate for analysis.
7. Before the test
 Check that sufficient Foam Concentrate is available in the storage
tanks / containers.
 Check for leaks on tank / container pipework.
 Check all foam concentrate isolation valves are Open.
 Check the foam concentrate supply pump is set to AUTO and is
electrically energised.
8. Apply the required ‘Maintenance Overrides’ or ‘Defeats’ on the system to
prevent the unplanned shutdowns.

The use of foam can cause deposits to be left on piping and structures in the protected
area. This should be washed down with services water on completion of the tests.

To address the above when testing foam monitors the direction of the nozzle can be
adjusted temporarily and the foam blanket direct to a clear area away from the vessel,
tank or protected area. Consideration should be given here to the effectiveness of the
blanket and delivery pattern. If the foam is for the protection of a storage tank then
consideration may be given to a temporary break in the delivery pipework while the test
is being undertaken. This must only be done with permission from the Production
Coordinator and assurances that the integrity of the protection shall not be
compromised by undertaking this action.

NOTE: If foam monitors are moved for the purpose of the test then they must be
returned to their original position on completion to ensure they are ready in the case of
an emergency.
9. Activate the Foam System for the respective area under test from the fusible
loop, local release point or F&G logic.
Ensure that all alarm and indication is activated and is in the correct sequence.
NOTE: The Overrides will prevent executive actions such as ESD and / or
SDV shut in from occurring if these are part of the operation logic for the
system.
10. Check correct operation of the delivery devices i.e. foam monitors and foam
generation skids. Ensure that the consistency of the foam is sufficient to be
able to produce the required blanket and that the pattern provides sufficient
cover.
Check that all associated executive actions occur and alarms and indications
are all correct.
11. On completion of the test(s) isolate the foam supplies and flush through the
delivery pipework to remove all foam deposits. Run through with water until the
discharges are clear.
Reset the system and ensure all foam valves are open and that stocks of foam
concentrate have been replenished.
12. Sign off test, record readings if required and report all defective equipment /
leaks.

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3.6 Sprinkler Systems

3.6.1 General
Sprinkler Systems are normally provided in enclosed spaces where carbonaceous fires
are a hazard, such as stores, offices and accommodation area. Sprinkler systems
provide wide area automatic protection and can be initiated by frangible bulbs, heat
and smoke detectors and manually.
The systems normally comprises of a pressurised storage tank, a ‘clack valve’ and a
ring main of sprinkler heads. The ring main is normally maintained dry, with the
exception of systems provided with frangible bulbs which may be charged with water.
For systems using a ‘clack valve’ the valve may be held in the Closed position by
pneumatic pressure. Release of the pressure will allow the valve to open and release
the pressurised water from the storage into the sprinkler system to contain or
extinguish the fire.
Testing of sprinkler systems is normally carried out ‘dry’ and is to ensure that all alarms
and indication are operating correctly.

3.6.2 Operational Integrity Testing

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1. Apply the required ‘Maintenance Overrides’ or ‘Defeats’ on the system to


prevent the unplanned shutdowns.
Sprinkler systems may be linked through the F&G logic to the firewater
pump(s) and ventilation / AC systems causing the systems to activate /
deactivate when the sprinkler is initiated.
2. Before testing the system a thorough check should be carried out.
 Ensure that all the sprinkler ‘roses’ are in place and not damaged.
 Inspect the system for signs of water leakage past the ‘clack valve’
 Check the condition of the ‘clack valve’ and control supplies to the valve
3. Isolate the water supply to the sprinkler system upstream of the ‘clack valve’.
4. Activate the sprinkler system from a local or remote position.
NOTE: Sprinkler systems are activated via smoke and heat detection which
would require activation to be from the local ‘test’ position.
5. Check correct operation of the system. Check that alarm and indication is
activated and any executive actions that are associated with the system.
6. On completion of the test(s) reset the system to normal.
Check the ‘clack valve’ is Closed before opening the isolation on the water
supply.
Recheck the pressure on the water pressure vessel.
Inspect around sprinkler ‘roses’ for signs of leaking.
7. Sign off test, record readings report all defective equipment / leaks.

3.7 Fire Suppressant Delivery Systems

3.7.1 General
The most commonly used Fire Suppressant Delivery system are CO 2 and Halon3. The
systems are commonly found on gas turbine, power generation, switchgear and
compressor enclosures which are under normal operating conditions unmanned.
The suppressant is stored in cylinders which are located outside of the protected area
and then piped in and released via strategically located nozzles in to the enclosure.
The suppressant is used to deprive the fire of oxygen by reducing the content and as
little cooling effect. Entry into the enclosure under normal operating conditions, when
the suppressant is ‘armed’ is prohibited. All other entries are by Permit to Work and the
suppressant system must be ‘disarmed’. The systems are not tested live i.e. a
suppressant release, all test are carried out as ‘dry runs’ and the release system is
locked out.
Reference should be made to the Vendors literature and test procedures before
carrying out operational integrity tests.

3
The use of Halon 1211 & 1301 as a Fire Suppressant is now being phased out because it is
depletes the ozone layer if released.
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3.7.2 Operational Integrity Testing


1. Carryout visual inspection of the fire suppressant system and check:
Security of suppressant cylinder racks
Main cylinder and pilot cylinder pressures
‘Locked Open’ and ‘Locked Closed’ valves at correct status
System ‘armed’ and all indication at ‘Normal / Operational’ status (refer to
Vendors O&M Manual)
No signs of physical damage on delivery system pipework.
2. In accordance with the Vendor recommended practices perform necessary
functions tests on the system. Ensure alarm and indication is activated at the
Local and Remote locations.
Ensure the systems are reset on completion of all tests.

Fire Suppressant Delivery System should be inspected by the Vendor or a 3 rd Party


Specialist Company every 12 months and the system actuated without an
extinguishant release (suppressant isolated). The test should ensure that all executive
actions associated with the system are functional.

Faults identified on the system shall be rectified immediately or the protected


equipment removed from service until the faults have been rectified.

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4 Testing, Maintenance and Fault / Defect Reporting

4.1 Operational Testing


The following frequencies are recommended for Operational Integrity Testing of Fixed
Firefighting Systems.

Fixed Firefighting Frequency Test


System
Firewater System Weekly  Test Run Firewater Pump(s)
 Operation of hydrants
 Operation of fire monitors
 Alarms and Indication
Deluge System Monthly  Alarms and Indication
 Pattern of spray (wet test)
 Coverage (wet test)
Foam System Monthly  Alarms and Indication
 Operation of system (no foam)
 Operation of system (with foam)
 Foam density and coverage
Six  Analysis of foam concentrate
Monthly
Sprinkler System Monthly  Alarms and Indication
 Operation of system (dry test)
Fire Suppressant Monthly  Alarms and Indication
Delivery System  Operation of system (dry test)
Yearly  Operation test and inspection (Vendor or 3rd Party
Inspector)

4.2 1st Line Maintenance


1st Line Maintenance is the servicing that can be carried out by Operations Personnel
at the time of inspection and testing of the fixed firefighting system. The following are
recommendations and should only be considered if a detailed ‘campaign maintenance’
schedule is not in place.

4.2.1 Firewater Systems


Check for signs of damage to the system
Check for leaking hydrants and passing valves. Tighten glands.
Check firewater monitors and ensure that the elevations of fixed monitors are
correct. Grease locking handles if required.
Check the gearbox oil levels on firewater oscillating monitors and grease / lubricate
training gear as required.

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Inspect firewater pump(s). For diesel driven check that engine oil, cooling water and
fuel header tanks are the correct levels. Replenish or report. Visually inspect
conditions of engine belts and ensure all guards are secure and in place.
If hoses are connected to hydrants check and report the condition of the hoses.

4.2.2 Deluge Systems


 Check for signs of damage to the system pipework
 Check for blocked or leaking nozzles
 Inspect ‘clack valve’ assembly and check for leaks on pneumatic lines (if
provided)

4.2.3 Foam Systems


Check the system for signs of leakage especially around foam storage tanks and
containers
Check foam levels and replenish as required4
Inspect and lubricate foam monitor locking and training gear
Check for leaking and passing system valves. Tighten glands
Check foam diffusers where provided and ensure that they are not damaged or
distorted

4.2.4 Sprinkler Systems


 Inspect pressurised water storage vessel for leaks. Ensure charge pressure is
correct
 Check system pipe work for leaks
 Inspect sprinkler heads for damage. If system is fitted with frangible bulbs
check for damage or leaks at seat

4.2.5 Fire Suppressant Delivery Systems


Refer to the Vendors O&M manual for requirements of 1 st Line Maintenance.

4.3 Fault / Defect Reporting


Faults and defects that are found during normal site inspections, testing or during
maintenance shall be reported by raising a Z1 Notification.
The notification shall be included in the Daily Notification Meeting and prioritised. The
process of work preparation, scheduling and execution shall be in accordance with
established maintenance procedures and in accordance with CP-114 Maintenance and
Integrity Management Code of Practice.

4
When handling foam concentrate adhere to the requirements of the SHOC card
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Appendix 1 – Abbreviations

F&G Fire and Gas


MAC Manual Alarm Call Point
CCR Central Control Room
ESD Emergency Shut Down
SDV Shut Down Valve
O&M Operations and Maintenance

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Firefighting
The controlled version of this CMF Document Systems
resides online in Livelink®. Printed copies are UNCONTROLLED.
Revision: 3.0
Petroleum Development Oman LLC Effective: Aug-11

Appendix 2 – Reference Material

CP-114 Maintenance and Integrity Management Code of Practice


PR-1001c - Temporary Overriding of Safeguarding Systems
PR-1001e – Operations Procedure Temporary Variance
PR-1100 - Operator Routine Functions
PR-1172 - Permit to Work System Manual

Page 21 PR-1147 - Operational Integrity Testing of Fixed Printed 31/08/11


Firefighting
The controlled version of this CMF Document Systems
resides online in Livelink®. Printed copies are UNCONTROLLED.
Revision: 3.0
Petroleum Development Oman LLC Effective: Aug-11

Appendix 3 - User Feedback Page

PR-1147 – Operational Integrity Testing of Fixed Firefighting Systems


User Feedback Page

Any user who identifies an inaccuracy, error or ambiguity is requested to notify


the custodian so that appropriate action can be taken. The user is requested
to return this page fully completed, indicating precisely the amendment(s)
recommended.
Name:
Ref ID Date:

Page Ref: Brief Description of Change Required and Reasons

UOP7 - PTW System Coordinator


Custodian of Document Date:

Page 22 PR-1147 - Operational Integrity Testing of Fixed Printed 31/08/11


Firefighting Systems
The controlled version of this CMF Document resides online in Livelink®. Printed copies are UNCONTROLLED.
Revision: 3.0
Petroleum Development Oman LLC Effective: Aug-11

Addendum – Changes to the Document at Revision 3.0

1. Layout changed to comply with latest format


2. Testing, Maintenance and Fault / Defect Reporting incorporated into a new Section 4
3. Operations personnel and maintenance technicians given responsibility to raise Z1
Notification for failures, defects found on systems
4. Section 3.2 clarified on PTW requirements for working on Fixed Firefighting Systems
5. New Section 4.3 Fault / Defect reporting added

Page 23 PR-1147 - Operational Integrity Testing of Fixed Printed 31/08/11


Firefighting Systems
The controlled version of this CMF Document resides online in Livelink®. Printed copies are UNCONTROLLED.

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