A.03.09 Attachment 13 Appendix D - Fire Protection System Report.pdf

PDF 484 KB Posted Feb 9, 2023

Attached to: Request for Proposal (RFP) for Project: Petroleum, Oil, and Lubricant (POL) Increase Capacity at Kecskemet Air Base, Hungary
Solicitation number: W912GB23R0011
Issued by: Department of the Army European Command

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17. Kernserstrasse, CH-6060 Sarnen, Switzerland +41 41 662 4574 info@sfprd.com sfprd.com

TECHNICAL SUMMARY

for Bilfinger Tebodin Hungary Kft.

Pressurized Instant Foam Fire Protection System

for	storage	tanks	and	technological	areas
Rev.	2

Client: Bilfinger Tebodin Hungary Kft.

Bikszadi u. 6/a, 1119 Budapest

Project:	ERI	(EUROPEAN	REASSURANCE	INITIATIVE)
AF	MILCON,	POL	Increase	Capacity

Kecskemet Air Base, Hungary

TABLE OF CONTENTS

1.	Introduction .................................................................................................................................... 3
2.	Preliminaries ................................................................................................................................... 3
3.	Scope of work ................................................................................................................................. 4
4.	Storage-tank and annular space fire protection ............................................................................. 4
5.	Protection of other technological areas (optional) ........................................................................ 6
6.	Operational description of the Pressurized Instant Foam Fire Fighting system ............................. 6
7.	Technical summary ......................................................................................................................... 7

7.1.	Mechanical system ................................................................................................................ 7
7.2.	Fire detection and extinguishment control system ............................................................... 8

8.	Construction of the Pressurized Instant Foam Fire Protection System .......................................... 9
9.	Inspection and maintenance to be done by Client ......................................................................... 9
10.	Inspection and maintenance to be done by an SFPRD specialist ............................................... 9
11.	Certifications .............................................................................................................................. 9
12.	Cost estimates .......................................................................................................................... 10

1. INTRODUCTION

The

Pressurized

Instant

Foam

Fire

Fighting

system

(or

Foam

System

short)

was

developed

Swiss

Fire

Protection

Research

Development

(SFPRD)

fight

fires

involving

polar

non-polar

flammable

liquids,

very

suitable

for

protecting

storage

tanks

with

fixed

floating

roofs

well

the

technological

areas

and

equipment.

Other

applications

the

system

are

capable

extinguishing

flammable

liquids

from

the

range

handheld

devices

fire

trucks,

but

those

applications

are

not

the

scope

this

document.

The

concept

this

system

is:

the

firefighting

foam

stored

under

pressure

vessel

with

soluble

gas

mixture,

therefore

when

released,

introducing

self-expanding

foam

the

force

the

pressure

without

any

machinery

foam

generators

the

burning

liquid

surface.

The

Pressurized

Instant

Foam

Fire

Fighting

system

applies

very

high

quality

foam

significantly

higher

quantity

per

minute

than

other

systems.

This

reduces

environmental

impacts

and

limits

foam

decomposition

the

burning

surface.

Any

storage

tank

fire

covered

foam

within

maximum

three

minutes.

The

extinguishing

system

does

not

depend

water

network,

electricity

supply,

suitable

for

fire

protection

isolated

storage

terminals

and

their

process

area

also.

The

system

requires

less

maintenance

compared

the

other,

traditional

firefighting

systems

the

market.

2. PRELIMINARIES

Bilfinger

Tebodin

Hungary

Kft.

(hereinafter:

Client)

participates

engineering

and

construction

work

Kecskemét

Air

Base

Hungary.

The

project

will

increase

POL

storage

capacity

through

construction

operational

jet

fuel

storage

facility

that

will

accommodate

NATO

equivalent

Tactical

Fighter

Aircraft

(TFA)

and

Strategic

Transport

Aircraft

(STA).

The

Client,

recognizing

the

need

for

fire

protection

system

the

new

tank-storage

facility,

asked

Swiss

Fire

Protection

Research

Development

offer

price

estimate

for

installing

the

Pressurized

Instant

Foam

fire

protection

system

the

new

JET-A

storage

tanks

(ST5,

ST6).

Tank

storage

facility

constitutes

two

similar

storage

tank

farms,

SITE

and

SITE

comprise

existing

process

area

and

two

smaller

ST1,

ST2,

and

ST3,

ST4

storage

tank

with

volume

1250

each.

Firewater

system

and

fire

extinguish

system

not

present,

the

existing

tanks

lacks

any

firefighting

equipment.

According

the

agreement

with

the

Client,

the

price

estimation

contains

the

cost

firefighting

installations

for

the

new

tanks

only,

but

note

that,

the

existing

tanks

may

covered

with

fire

protection

with

minimal

additional

cost.

Possible risk areas:

● Annular

space

storage

tanks:

any

leakage

tank

flanges

may

result

vaporizing

combustible

liquid

surface,

where

ignition

source

may

cause

explosion

and

fire.

● Prolonged

fire

(>5-10

min)

the

annular

space

heats

the

tank

wall

and

risks

additional

explosion

inside

the

storage

tank.

So,

such

case,

the

annular

space

and

the

interior

the

tank

should

also

covered

with

foam.

3. SCOPE OF WORK

The

offer

covers

all

fire-protection

and

fire-suppression

tasks

according

the

new

ST5

and

ST6

storage

tanks.

Optionally,

offer

the

cost

automatic

fire

protection

JET-A

filter

and

pump

rooms

also,

based

the

site

visit,

found

out

that

there

protection

and

small

fire

there

can

render

the

operation

the

tanks

impossible

for

longer

period.

Therefore

strongly

recommend

extend

the

fire

protection

the

filter

and

pump

room.

The system can be operated independently from water mains and electricity.

The

calculation

valid

with

SFPRD’s

firefighting

foam

only.

The

foam

the

Pressurized

Instant

Foam

System

are

not

separable

this

case,

because

the

exceptional

fire

extinguishing

performance

can

guaranteed

with

the

combination

them.

The

system

can

used

with

other

foams

the

market,

but

that

would

require

bigger

pressure

vessels

due

the

less

efficient

extinguishment

capability

them,

that

required,

the

cost

estimation

shall

recalculated.

4. STORAGE-TANK	AND	ANNULAR	SPACE	FIRE	PROTECTION
The	system	design	covers	the	fire	protection	of	the	following	surfaces:

Fire surfaces:

● Annular	space	of	ST5	and	ST6	(each):	95.11	m2
● Fire	surface	of	one	tank	(ST5	or	ST6):	380	m2	(D=22	m)
● Option:	JET-A	filter	and	pump	rooms:	100	m2

Protection techniques:

- To

prevent

the

risk

escalation,

leakage

detection

recommended

for

the

annular

spaces

(not

included

the

scope

this

offer).

Leakage

control

pit

shall

checked

regularly,

and

the

annular

space

shall

equipped

with

vapor

concentration

monitor

certified

fuel

vapors.

- In

case

severe

leakage

detected,

and

not-expected

ignition

source

present,

the

annular

space

may

flooded

with

foam

prevent

explosion

(if

necessary).

- In

case

fire

the

annular

space

inside

the

tank,

the

fire

may

detected

very

reliable

method:

the

annular

space

(and

the

inner

rim

the

tanks)

shall

fitted

with

melt

tubes,

all

around

the

perimeter.

case

fire,

the

melt

tube

loses

its

structural

integrity,

bursts

and

the

pressure

drop

can

detected

the

control

box,

which

launches

the

extinguishment

process.

See

information

Chapter

- In

case

fire

the

annular

space,

the

extinguishment

starts

automatically,

and

the

inner

space

the

tank

can

covered

manually

automatically

with

foam

the

same

time

(subject

the

requirements

the

Client,

but

recommend

that

the

foam

ejection

the

inner

space

may

start

case

bigger

fire

the

annular

space).

- Foam

flow

the

annular

space

designed

produce

cooling

blanket

the

outside

wall

the

tank

prevent

the

ignition

vapors

inside

the

tank.

- In case of a fire detected inside the tank, only the interior of the tank shall be covered with foam.

- In

case

fire

detected

the

filter

and

pump

room,

the

floor

the

room

can

flooded

with

foam

automatically

manually.

Design information:

- Specific	foam	intensity:	14.97	L/m2	min
- Foam	flow	to	annular	space:	1423	L/min
- Foam	flow	to	tank:	5688	L/min
- foam	flow	to	filter	and	pump	room:	1497	L/min	(optional)
- Duration	of	foam	introduction:	2	minutes	(if	both	surfaces	covered	simultaneously	–

otherwise it is shorter)

Flow velocity calculation of foam header:

- Total

foam

flow:

7111

L/min=0.1185

m3/sec

- Selected

pipe

size:

200,

219.1x6

- Inner

diameter:

207

- Cross

section:

0.03365

- Foam

velocity

the

header:

v=Q/A=0.1185

m3/sec

0.03365

3.52

m/sec

Flow velocity calculation of tank extinguish pipe:

- Foam

flow:

5688

L/min=0.0948

m3/sec

- Selected

pipe

size:

150,

168.3x5

- Inner

diameter:

158.3

- Cross

section:

0.01968

- Foam

velocity

the

tank

extinguish

pipe:

v=Q/A=0.0948

m3/sec

0.01968

4.81

m/sec

Flow velocity calculation of annular space extinguish pipe:

- Foam

flow:

1423

L/min=0.023716

m3/sec

- Selected

pipe

size:

100,

114.3x4.5.

- Inner

diameter:

105.3

- Cross

section:

0.0087

- Foam

velocity

the

annular

extinguish

pipe:

v=Q/A=0.023716

m3/sec

0.0087

2.72

m/sec

Flow velocity calculation of optional filter and pump room extinguishment (optional):

- Foam

flow:

1497

L/min=0.02495

m3/sec

- Selected

pipe

size:

100,

114.3x4.5.

- Inner

diameter:

105.3

- Cross

section:

0.0087

- Foam

velocity

the

annular

extinguish

pipe:

v=Q/A=0.02495

m3/sec

0.0087

2.87

m/sec

Maximum allowed foam velocity is 5 m/sec.

5. PROTECTION OF OTHER TECHNOLOGICAL AREAS (OPTIONAL)

Other

areas

the

facility

can

protected

the

same

way.

These

technological

areas

may

also

equipped

with

automatic

extinguishing

system

through

dry

header

pipes,

according

the

layout

the

station.

recommend

keeping

the

option

manual

intervention

due

possible

hidden

areas

that

are

difficult

extinguish

with

fixed

monitor

(as

were

not

site

visit

yet,

these

are

just

assumptions).

Due

the

preferred

location

the

foam

tanks

are

very

the

process

area,

this

automatic

system

and

the

manual

intervention

devices

can

equipped

with

minimal

additional

material

cost,

therefore

recommend

them

for

added

security.

6. OPERATIONAL DESCRIPTION OF THE PRESSURIZED INSTANT FOAM FIRE FIGHTING

SYSTEM

The

patented

Pressurized

Instant

Foam

system

consists

pressurized

foam-storage

pipe

filled

with

specially

developed

foam

solution

and

propellant

gas.

The

gas

partly

dissolves

the

foam

solution,

will

ready

release

any

time

without

additional

energy

input.

The

two-valve

system

reduces

the

risk

accidental

foam

dispensation

with

two-stage

enabling

system.

Fire

detected

flame

detector,

CCTV,

any

type

heat/smoke

detector

(according

the

requirements

the

Client).

The

operator

gets

signal

the

screen

the

fire-alarm

center.

then

possible

start

extinguishing

automatically

(instantly

time-delayed)

manually,

according

the

Client’s

requirements.

The

valves

the

foam

networks

are

preferably

the

spring-return

type,

which

returns

open

position

case

the

pressure-air

system

damaged.

Pneumatic, heat burst pipe type fire detection system (our recommendation)

The

main

task

the

pneumatic

fire

detection

system

detect

fire

inside

the

tank

and

open

the

butterfly

valve

foam

pipes.

also

responsible

for

the

transmission

the

status

signals

the

control

system.

With

the

pneumatic

detection

and

control

system,

the

extinguishing

the

tank

fires

becomes

completely

automatic.

The

safe

operation

absolutely

guaranteed

since

external

energy

needed

open

the

flooding

and

shut-off

valves.

significant

decrease

gas

pressure

the

detectors

processed

pneumatic

logic

unit.

The

butterfly

valve

actuated

the

working

cylinders

which

located

inside

the

pneumatic

logic

unit.

The

pneumatic

system

filled

with

compressed

air

which

operational

pressure

bar.

standby

mode,

the

pneumatic

system

consumes

zero

energy.

Each

pneumatic

detector

annular

ring

made

pneumatic

tube.

case

fire,

the

detector

tube

melts

and

the

pressure

the

compressed

air

inside

drops.

This

pressure

drop

launches

the

fire

extinguishing

process

inside

the

tank.

least

pneumatic

detectors

shall

placed

inside

the

tank

(to

prevent

accidental

release,

our

recommendation

out

activation

system).

Reliability

declare

that

this

configuration,

the

Foam

firefighting

system

does

not

require

any

external

energy

input

human

intervention

for

activation,

therefore

the

risk

failing

very

low.

When extreme reliability is required, flood and shut-off valves and detection system can be duplicated.

For

your

information,

developed

extinguish

launching

system

which

does

not

include

any

moving

parts

(no

opening

valves

required

for

activation)

and

still

operates

without

external

energy

input,

therefore

its

reliability

extremely

high

–

have

not

designed

this

type

system

this

project

yet,

but

naturally

can

there

the

demand

for

that.

This

system

launches

the

foam

flow

bursting

discs,

which

are

controlled

the

mentioned

heat

burst

detector

patented

way.

The

lack

any

moving

parts

makes

suitable

any

industrial

and

military

purposes,

where

extreme

reliability

and

maintenance-free

operation

required.

7. TECHNICAL SUMMARY

7.1. MECHANICAL

SYSTEM

The

extinguishment

system

able

extinguish

the

largest

required

fire

area

(eg.

the

biggest

storage

tank

and

its

annular

space),

all

tank

surfaces

them

simultaneously

(according

the

requirements).

Pressurized Instant Foam Pressure Vessel

The

foam

should

stored

pressure

vessel,

according

the

volume

calculated

for

each

scenario.

The

pressure

vessel

and

the

pipes

should

buried

minimize

temperature

fluctuations

and

vulnerability

accident

sabotage.

Based

the

site

visit,

realized

that

the

ground

water

level

high,

that

the

underground

location

the

pressure

vessels

would

unadvisable,

came

with

half-buried,

half-built

solution,

which

changes

the

prices

only

minimal

extent.

Volume: 2x10m3

Diameter: 2 m

Layout: Horizontal

Material:

Carbon

steel

with

internal

epoxy

layer.

The

internal

layer

continues

the

sealing

faces

the

flanges,

strikeover

checked

1000

Material charge: Foam solution

External coating: External PE coating

Design,	manufacturing,	certification:	According	to	EN	13445,	2014/68/EU	directive	(PED-
2014),	or	ASME,	API	standards

Periodic inspection: Visual inspection every five years, thorough inspection every 10 years

Valves: Valves in contact with the foam solution:

Larger	valves	(DN50	and	above)	should	be	butterfly	valves	because	they
are	made	with	internal	PFTE	coating	and	a	stainless-steel	closing	element.
They	are	also	cost	effective.

Operation	of	the	butterfly	valves	should	be	done	using	a	pneumatic
actuator	with	automatic	spring	return.

Small

valves

contact

with

foam

should

stainless

steel

ball

valves.

The

other

valves

(not

contact

with

the

foam

solution)

are

made

carbon

steel,

but

brass

ball

valves

may

also

used

the

pressure-air

system.

Pipes

Pipes are internally coated with epoxy paint. The pressure-air pipes are made of galvanized steel.

7.2. FIRE DETECTION AND EXTINGUISHMENT CONTROL SYSTEM

The dike area of the storage tanks will be protected by a heat-burst or electric fire-detection system.

The electric fire-detection system consists the following main parts:

● main	control	panel
● sub	control	panel

● detectors

● fire	alarm	cable	network
● uninterruptible	power	supply	(UPS)	system
● graphic	display

The

main

control

panel

will

located

inside

the

Control

Room.

Its

primary

role

receive

signals

from

sub

control

panels,

release

the

extinguishment

command

and

transmit

signals

the

plant’s

fire

alarm

center

(if

exist).

The

sub

control

panels

are

connected

the

electric

fire

detectors

and

the

pneumatic

logical

units.

These

panels

will

placed

non-hazardous

area.

Flame

detectors

are

optional

for

detecting

fire

inside

the

dike

area,

and

this

case,

two-step

release

can

built

decrease

the

risk

accidental

foam

spillage.

Industry

standards

not

oblige

plants

protect

the

other

technological

areas

(pump

stations,

metering

skid,

etc.)

from

fire.

Due

the

low

distance

between

the

preferred

location

foam

tanks

and

the

process

area,

recommend

least

manual

intervention

devices

(handlines)

the

process

area

(see

Chapter

5).

There

another

option

release

the

foam

manually

with

control

button

located

inside

the

plant’s

Control

Room.

The

cables

the

fire-alarm

network

will

single

fire-alarm

cables,

except

when

they

have

control

functions.

this

case

fireproof

cables

will

installed.

The extinguishing control panels powered by independent “UPS” power system.

8. CONSTRUCTION OF THE PRESSURIZED INSTANT FOAM FIRE PROTECTION SYSTEM

Construction

must

handled

certified

local

construction

company

with

welders

and

project

leaders

who

are

qualified

for

work

the

petrochemical

industry.

They

must

also

have

experience

working

explosive

areas.

Pipes and pipe support would be of the welded type, painted with two-component epoxy-based paint.

9. INSPECTION AND MAINTENANCE TO BE DONE BY CLIENT

The

inspection

the

system

the

final

client

quite

easy.

The

Pressurized

Instant

foam-storage

tank

will

equipped

with

pressure

and

temperature

switches

whose

signals

will

display

the

main

panel

the

control

room.

All

valves

can

tested

for

functionality

site,

either

manually

via

remote

control

from

the

fire

alarm

panel.

10. INSPECTION AND MAINTENANCE TO BE DONE BY AN SFPRD SPECIALIST

Foam

quality,

drainage

time

and

expansion

ratios

should

checked

every

year

SFPRD

expert.

The

Pressurized

Instant

foam-storage

pipe

will

inspected

every

five

years

(visual

check),

with

thorough

inspection

and

pressure

test

every

years.

11. CERTIFICATIONS

TÜV

SÜD

Germany

successfully

carried

out

test

the

storage-tank

model

for

the

purpose

verifying

the

suitability

new

fire-extinguishing

technology

for

storage

tanks.

The

experimental

tank

was

equipped

with

Pressurized

Instant

Foam

Fire

Protection

System.

The

diameter

the

model

was

25.2

meters,

the

fire

surface

was

500

m2.

September

22,

2010,

TÜV

Süd

issued

Expert

Report

(IS-EG2-MUC/Rh)

the

test

conclusions

(see

attachment).

The

Pressurized

instant

Foam

System

has

the

necessary

approval

and

marketing

authorization

Hungarian

National

Directorate

General

for

Disaster

Management,

Ministry

the

Interior

(BM

OKF).

12. COST ESTIMATES

The cost estimate is based on the drawings received from the Client. It uses EU material and labor prices.

SITE A USD

Construction and piping material cost 198 000

Budget reserve for unforeseen construction cost, 30 % 60 000

Fire control panel 20 000

Engineering 20 000

Foam and filling cost 20 000

Licence fee (12% of total construction cost, but at least 50k USD per tank) 50 000

Construction supervision and QA (Quality Assurance) cost 20 000

Total (Site A): 388 000

SITE B USD

Construction and piping material cost 191 000

Budget reserve for unforeseen construction cost, 30 % 58 000

Fire control panel 20 000

Engineering 20 000

Foam and filling cost 20 000

Licence fee (12% of total construction cost, but at least 50k USD per tank) 50 000

Construction supervision and QA (Quality Assurance) cost 20 000

Total (Site B): 379 000

TOTAL (Site A + Site B) 767 000

OPTIONAL: Pump Room protection (Site A + B) 44 000

SFPRD

maintenance

fee

will

around

USD

10,000

per

year,

which

consist

the

yearly

sampling

and

checking

the

foam

our

laboratory

Hungary.

Validity

This

documentation

has

been

made

according

the

information

provided

electronically

the

Client

based

the

information

acquired

during

site

visit

22/11/2018.

Any

information

which

can

only

discovered

the

site,

may

cause

slight

changes

the

documentation

and

revisions

can

necessary

drawings,

text

cost

estimate.

The

cost

estimation

based

SFPRD

corporate

financial

cost

estimation

software,

European

raw

material

and

labor

prices,

and

cost

recent

projects.

The

accuracy

the

cost

estimation

–

due

the

details

level

the

design

information

available

–

about

+/-

30%.

File details come from the government source that posted it. Updated Feb 9, 2023.