Elevating Safety Standards: Comprehensive HSE Support for FEED New Port Control Tower in Ras Laffan Port,Qatar

iFluids Engineering & Consultancy WLL was assigned to carry out Technical HSE studies such as Fire Safety Philosophy, Passive Fire protection, Compliance Report, ENVID (Environmental Impact Identification ), Quantitative Risk Analysis (QRA), and Hazardous Area Classification (HAC) studies for the FEED New Port Control Tower facility project in Ras Laffan.

• The scope of project aims for a comprehensive approach ensuring
• The safety of personnel,
• Safeguarding the facility
• Maintaining business continuity during potential fire emergencies, and
• Protecting the environment from the risks associated with fire and related hazards.
• Ras Laffan City (RLC) is located approximately 70 km north of Doha, Qatar, and plays a vital role in the country’s industrial development, especially in the supply of gas to various industries.
• RLC hosts critical infrastructure, including facilities like Qatargas, RasGas, Ras Laffan Power Company Ltd, Oryx GTL, Dolphin Energy Ltd (DEL), and upcoming projects such as power plants, Exxon Mobil Ethane cracker, Pearl GTL, Condensate Refinery, and petrochemical industries.
• Qatar Energy operates and maintains essential services within RLC, including potable water supply, sewage collection and treatment, landscaping, storm water systems, and solid waste handling.

Fire Safety Philosophy

• Key Principles and Emergency Response:
• This Fire Safety philosophy encompasses various key principles and methodologies designed to mitigate potential risks and provide a robust emergency response system.
• At the core of this philosophy is the implementation of an emergency alarm system. The primary objective is to activate an alarm signal throughout the facility, effectively alerting personnel in the event of an emergency.
• This includes the installation of audible alarms and status lights strategically located on all floors of the New Port Control Tower.
• These alarms are critical for summoning personnel to muster areas and warning them of specific emergency situations, enabling immediate action.
• Emergency Power System:
• Ensuring uninterrupted power supply during emergencies is Important.
• The emergency power system is meticulously designed to provide electricity for a minimum duration of 24 hours.
• This power source is vital for critical systems that include emergency escape lighting, fire and gas detection systems, firefighting equipment, alarm and public address (PA) systems, as well as various communication systems.
• The ability to maintain these systems during an emergency is crucial for effective response and evacuation procedures.
• Comprehensive Telecommunications System:
• The New Port Control Tower project incorporates a comprehensive telecommunications system. This system serves as a lifeline for communication during both normal operations and emergency situations.
• It encompasses telephone, telex, paging, radio, and intercom systems.
• These communication channels are vital for maintaining contact with various stakeholders, including port operations, emergency centers, marine vessels, helicopters, and fire vehicles. Effective communication plays a pivotal role in coordinating emergency responses and ensuring the safety of all involved parties.
• Photo luminescent Safety Signs:
• Safety signs are strategically placed throughout the facility, serving as visual aids that convey important safety information.
• What sets these signs apart is their photo luminescent nature, which allows them to remain visible even in the event of a power failure.
• These signs are crucial for indicating escape routes, highlighting the locations of firefighting equipment, and conveying other essential safety information that can guide personnel to safety during an emergency.
• Noise Control Measures:
• Noise control is another essential aspect of the Fire Safety Philosophy.
• The philosophy defines a maximum noise limit of 85 dB (A) over an 8-hour working period.
• This limit is designed to protect the hearing health of workers. In areas where noise levels exceed this threshold, hearing protection is provided.
• Effective noise control measures create a safer and more comfortable working environment.
• Climatic Conditions and Heat Stress Mitigation:
• The New Port Control Tower project recognises the challenges posed by extreme climatic conditions, particularly the high temperatures experienced during the summer months.
• To mitigate the risks associated with heat stress, the project incorporates measures such as natural ventilation and forced air ventilation.
• These systems ensure that workers are provided with a comfortable and safe environment, even in extreme heat.
• Emergency Response Equipment:
• Adequate emergency response equipment is provided throughout the facility.
• This includes essential items such as breathing apparatus, fire suits, and fire blankets. These tools are essential for the safety of personnel during normal operations and emergency situations. They equip workers to respond effectively to potential hazards.

Conclusion

In conclusion, the Fire Safety Philosophy for the New Port Control Tower project is a comprehensive and meticulously planned approach to ensure the safety and protection of all aspects of the project. From emergency alarm systems to power supply, telecommunications, safety signs, wind direction indicators, noise control, heat stress management, and emergency response equipment, every facet of safety is carefully considered and addressed. This Fire Safety philosophy aims to create a secure working environment and robust emergency response capabilities to safeguard personnel, facilities, and the environment from the potential risks posed by fire and related hazards.

Passive Fire protection

• Overview of Fire Protection System Upgrade at Berth 6:
• The upgrade and replacement of the fire protection system at Berth 6 in Mesaieed Port necessitates a detailed focus on Passive Fire Protection (PFP).
• This integral aspect of the project is geared towards ensuring the safety of personnel, protecting valuable assets, and maintaining business continuity in the face of potential fire emergencies.
• Historical and Operational Context of Berth 6:
• Berth 6 was established in 1988 to facilitate the import and export of bulk raw and refined hydrocarbon products, making it a critical part of Qatar Energy’s operations.
• However, the existing fire protection system has faced significant challenges due to extensive operational use, ageing, and a corrosive environment.
• These factors have led to reduced reliability, making it imperative to upgrade the system urgently.
• The project aims to align the fire protection system with the latest safety standards and philosophies while ensuring ease of use and reliability.
• Importance of Passive Fire Protection (PFP):
• Passive Fire Protection, often referred to as fireproofing, is an essential element of fire safety that operates without relying on the activation of active fire systems.
• Instead, it slows down the rise in substrate temperature during a fire event, protecting structural elements and critical equipment from damage.
• The selection and design of PFP are crucial to ensuring compliance with industry standards and project specifications.
• Criteria for PFP Material and Strategy Selection:
• Several criteria guide the selection of PFP materials and strategies. These include the type of fire (pool or jet), fire size, and expected duration.
• A Fire and Explosion Risk Assessment (FERA) report quantifies fire and leakage consequences for various scenarios, such as pool fires, jet fires, and flash fires.
• The FERA report identifies potential equipment that is most likely to fail and exacerbate a fire emergency.
• Findings of the FERA Report:
• Based on the identified potential equipment and FERA report findings, a Fireproofing Zone (FPZ) concept is developed.
• This concept helps determine the areas where PFP should be applied.
• Fireproofing Zone (FPZ) Concept:
• The FPZ typically includes vertical and horizontal steel members, supports for pipe racks, knee and diagonal bracing, steel legs supporting towers or vessels, and critical electrical, instrument, and control systems.
• Exemptions from PFP Requirements:
• In cases where there are early-stage automatic Deluge water cooling systems, such as those over Metering Skids and Launcher/Receiver structures, PFP for deluge pipe supports may not be necessary.
• However, the protection of electrical, instrument, and control systems connected to emergency isolation valves is essential to ensure their reliable performance during a fire
• Enhancements for the New Fire/Foam Water Network:
• To further enhance fire safety, all pipe supports for the new above-ground Fire/Foam water network are to be constructed using concrete sleepers.
• This choice of materials eliminates the need for passive fire protection in this specific application.

Conclusion

The upgrade and replacement of the Fire Protection System at Berth 6 in Mesaieed Port involve a meticulous approach to passive fire protection (PFP). This crucial aspect of the project aims to safeguard structural integrity, critical equipment, and personnel safety during fire emergencies. Through a systematic selection process based on fire type, size, and duration, along with the guidance of FERA reports and recognised industry standards, PFP measures are tailored to address specific needs and risks within the facility. This comprehensive approach ensures that the fire protection system aligns with Qatar Petroleum’s safety philosophy and international safety standards while enabling uninterrupted operations.

Compliance Report

What is a Compliance Report?: A document detailing how well an organisation complies with regulations, industry standards, and corporate policies.

• Compliance Report Overview:
• The Compliance Report for the construction of the New Port Control Tower in Ras Laffan Industrial City, Qatar, outlines the comprehensive approach taken to ensure that the building design complies with the relevant safety codes and standards, with a primary focus on NFPA 101, the Life Safety Code.
• Purpose of the Report:
• The report serves as a crucial document to validate that the building’s design adheres to necessary safety measures, particularly in safeguarding occupants and the structure in the event of emergencies or catastrophic events.
• NFPA 101 Life Safety Code:
• The design process for the New Port Control Tower is guided by the NFPA 101 Life Safety Code, 2012 Edition.
• The NFPA 101 code requirements are occupancy-based, and the report underscores that the specific code requirements applied to the tower are based on its intended occupancy and use.
• Occupancy Determination:
• The occupancy of the building is meticulously determined based on the NFPA 101 guidelines.
• The tower includes a variety of uses on different levels, such as Harbour Administration, VIP/VVIP areas, Emergency/Search and Rescue, and Vessel Traffic Control.
• Compliance with Occupancy Chapters:
• Each of these uses is classified within specific occupancy chapters as per the NFPA 101 code
• Means of Egress Requirements:
• The Compliance report discusses means of egress requirements in detail.
• It addresses the need for multiple exit stairwells due to the building’s occupancy, and each stairwell is sized to ensure that in the event of one stairwell being blocked, the remaining capacity is not less than 50% of the required capacity.
• Exit Components Compliance:
• It specifies the widths required for stairs, level components, ramps, and exit doors, ensuring compliance with safety standards.
• Shelter In Place (SIP) Facility:
• Considering the industrial risks in the vicinity of the tower, the report details the inclusion of a Shelter In Place (SIP) facility within the building.
• This SIP facility is designed to provide a safe haven for occupants in the event of a toxic release. It includes provisions for breathing air supply, positive pressure maintenance, and sealing off HVAC air intakes if required.

Conclusion

The Compliance Report for the New Port Control Tower in Ras Laffan outlines the systematic approach taken to ensure that the building design adheres to safety codes and standards, with a particular focus on NFPA 101. Through meticulous occupancy classification, egress planning, and unique design considerations, the report ensures that the tower will provide a safe environment for occupants, even in the face of potential emergencies or hazardous events. The report’s methodology emphasises strict compliance with relevant safety codes and comprehensive risk management.

ENVID (Environmental Impact Identification )

The primary objectives of the ENVID process are to identify and predict potential environmental impacts, recommend changes to prevent or minimise these impacts, prescribe control measures, and communicate findings to decision-makers. The goal is to minimise adverse environmental impacts to As Low As Reasonably Practicable (ALARP).

• Existing Port Control Tower:
• The existing Port Control Tower’s line of sight has been affected by developments such as the Common Sulphur Facility, prompting the need for a new tower.
• The scope includes the FEED design of the new Port Control Tower, confirmation of tower height and orientation, design of telecom systems, fire detection and prevention systems, utility tie-ins, development of the selected site, interfacing with study contractors, and obtaining regulatory permits and approvals.
• ENVID Process:
• The ENVID process follows a systematic methodology involving brainstorming sessions led by an independent chairman.
• The team comprises representatives from various disciplines, including project execution, engineering, environmental consulting, and more.
• The process begins with a compilation and review of project-related information, including Process Flow Diagrams, layouts, site conditions, and site environmental data as shown below.

Environmental Elements Identification:

• The ENVID assessment team systematically identifies environmental elements related to the various phases of a project, which include
• Construction
• Commissioning
• Regular operation
• Potential emergencies.
• These elements encompass factors like
• Emissions
• Waste generation
• Resource utilisation
• Noise, vibrations
• Changes in land use
• Risk Assessment Process:
• Subsequently, the team assesses the potential risks associated with each environmental aspect by examining both the potential consequences’ magnitude and the likelihood of occurrence.
• Risk Calculation and Ranking:
• For each identified effect, the potential risk is calculated by multiplying the expected impact size by the probability of its occurrence.
• Both the likelihood of an impact happening and the potential environmental changes it could trigger are systematically ranked.
• Semi-Quantitative Assessment Approach:
• This method enables a thorough semi-quantitative assessment, drawing upon the collective professional judgement of the ENVID assessment team, which is informed by their knowledge and experience.
• Consistency and Documentation:
• Notably, it ensures consistency and comprehensive documentation across every stage of the ENVID process, promoting a structured and rigorous examination of environmental factors and their potential repercussions.

• Impact Categorization:
• Impacts are categorised into High, Medium, or Low significance based on their potential impact on the environment.
• High-rated impacts may require alternative locations or technologies, while medium impacts may involve control and management measures.
• Low-rated impacts may focus on continual improvement.
• ENVID Process:
• involves a multi-disciplinary team with expertise in various fields, including process engineering, environmental science, health and safety, civil engineering, and more.
• This diverse team collaborates to ensure a comprehensive assessment.
• The environmental hazards and risks identified during the ENVID process are ranked based on their significance, with appropriate actions and measures proposed for each category.

Conclusion

In conclusion, the ENVID process for the New Port Control Tower project in Ras Laffan Industrial City employs a systematic approach to identify and assess potential Environmental impacts and risks associated with the project. It involves a diverse team of experts and aims to minimize adverse environmental impacts by recommending preventive and control measures. The process aligns with Qatar Energy’s environmental assessment guidelines and serves as a crucial step in the project planning process to ensure a clear understanding of the project’s relationship with its surrounding environment from the outset.

Quantitative Risk Analysis (QRA)

• Purpose of QRA:
• The purpose of QRA is to provide Engineering Consultancy Services (ECS) for the replacement of the perimeter fence and the construction of new patrol roads within RLC.
• This project is crucial to enhance security and safety measures mandated by the General Directorate of Industrial Security (GDIS).
• Objective of the QRA Study:
• QRA Study will examine and establish the importance of the Facility’s risks to personnel, assets, and production. This will aid in determining how best to reduce risks.
• IRPA Values Assessment:
• The IRPA (Individual Risk Probability Assessment) values for personnel involved in the project during the execution phase are reported in this document, following a QRA.
• The assessment utilizes LSIR (Location-Specific Individual Risk) data from the existing Quantitative Risk Assessment (QRA) Report for the project location.
• Compliance and Risk Management:
• It aims to demonstrate that risk levels are tolerable and As Low As Reasonably Practicable (ALARP) according to the QP Standard for HSE Risk Management (QP-HSE-STD-100).
• QRA identifies and provides risk reduction mitigation measures required for the construction phase.

Recommendations

• Trained personnel should be used during the execution phase.
• Emergency Response Plans (ERP) should be updated during the execution phase.
• Risk mitigation measures should be followed by obtaining work-specific permits to work (PTW) and project-specific HSE plans.
• Portable H2S detectors should be used for monitoring in areas where hydrogen sulfide is a concern.

Conclusion

The project involves QRA to assess and mitigate risks associated with replacing the security fence and constructing new patrol roads in Ras Laffan City. The assessment ensures that risks are kept at tolerable levels and follows Qatar Energy’s guidelines for HSE risk management. The report’s findings support the safe execution of the project while minimizing potential hazards

Hazardous Area Classification (HAC)

The aim of HAC Study was to define hazardous areas, classify equipment and services within those areas, and establish the basis for hazardous area layouts to ensure safety.

• HAC is a method to analyze and classify areas where flammable gas atmospheres may occur to ensure the safe selection, installation, and operation of equipment and electrical systems.
• The classification considers the ignition characteristics of gases or vapors, including ignition energy and autoignition temperature.
• HAC involves determining the type of hazardous zone and its extent based on three approaches: Point source, Risk-based approach, and Direct example approach.
• The goal of HAC is to minimize the probability of flammable atmospheres and ignition sources coexisting, ensuring proper electrical equipment selection and segregation of ignition sources from flammable gases.

Zonal Classification:

Hazardous areas are categorized into zones:

• Zone 0: Continuous gas/air mixture.
• Zone 1: Normal operations may produce explosive gas/air mixtures.
• Zone 2: Explosive gas/air mixtures are unlikely in normal operations and last only briefly.
• Non-Hazardous: An area not classified as Zone 0, 1, or 2.

The extent of Hazardous zones is dependent on source of hazard, physical properties of material released and defined as continuous, primary and secondary grade of release. For the purpose of area classification, a source of release is defined as a point from which a flammable gas, vapor or liquid may be released into the atmosphere. Three release grades are based on frequency and duration:

Source and Grade of Release:

• Release grades, including continuous, primary, and secondary, determine the zone categorization under unrestricted conditions.
• Continuous grade typically leads to Zone 0.
• Primary grade typically leads to Zone 1.
• Secondary grade typically leads to Zone 2.
• Volatility of released fluid is a key factor, especially in the case of liquids, as it affects vapor formation.

Fluid Categories and Ventilation:

• Fluid categories are based on material properties, and the degree of ventilation plays a crucial role in zone classification.
• Ventilation types include natural ventilation, adequate ventilation (with defined air changes per hour), and inadequate ventilation.
• Different types of areas include outdoor areas, open areas, congested areas, stagnant areas, and enclosed areas, each with its ventilation requirements.

Group and Temperature Class:

• Electrical equipment is categorized into groups and temperature classes based on the zone, gas group, and temperature classification.
• Group II apparatus equipment involves three subgroups (IIA, IIB, IIC) based on gas sensitivity.
• The New Port Control Tower is classified as non-hazardous for flammable hydrocarbons, making it exempt from classification requirements.
• Design Considerations and Battery Room:
• Specific considerations for the project include the battery room, where vented lead-acid batteries are installed.
• Ventilation and hydrogen detectors are essential for the battery room, which is classified as Zone 1 Group IIC T3 as a minimum.
• The operation of the fan in the battery room can be linked to the operation of the hydrogen monitor to enhance safety

Conclusion

In summary, the Hazardous Area Classification (HAC) conducted for the New Port Control Tower project at Ras Laffan Port involves categorizing areas and equipment to ensure the safe operation of electrical systems and equipment in potentially flammable atmospheres. Specific considerations, such as the battery room’s classification and design, are outlined to enhance safety measures.