FM Global

Property Loss Prevention Data Sheets

7-14
January 2013
Page 1 of 9

FIRE PROTECTION FOR CHEMICAL PLANTS

Table of Contents
Page
1.0 SCOPE ................................................................................................................................................... 2
1.1 Changes ............................................................................................................................................ 2
2.0 LOSS PREVENTION RECOMMENDATIONS ....................................................................................... 2
2.1 Introduction ...................................................................................................................................... 2
2.2 Construction and Location ............................................................................................................... 2
2.3 Occupancy ....................................................................................................................................... 3
2.4 Protection ......................................................................................................................................... 3
2.4.1 General .................................................................................................................................. 3
2.4.2 Arrangement of Sprinkler and Water Spray Systems ........................................................... 4
2.4.3 Protection of Piping, Valves and Fittings Against Damage from Explosions ........................ 6
2.4.4 Water Supply ......................................................................................................................... 6
2.4.5 Drainage ................................................................................................................................. 7
2.5 Equipment and Processes .............................................................................................................. 7
2.6 Operation and Maintenance ............................................................................................................ 7
3.0 SUPPORT FOR RECOMMENDATIONS ............................................................................................... 7
3.1 General ............................................................................................................................................ 7
3.2 Test Data ........................................................................................................................................... 8
4.0 REFERENCES ....................................................................................................................................... 8
4.1 FM Global ........................................................................................................................................ 8
4.2 Others .............................................................................................................................................. 8
APPENDIX A GLOSSARY OF TERMS ....................................................................................................... 8
APPENDIX B DOCUMENT REVISION HISTORY ....................................................................................... 9
APPENDIX C SUPPLEMENTAL INFORMATION ........................................................................................ 9

List of Figures
Fig. 1. Accidental release control systems and valving. ................................................................................ 4
Fig. 2. Indoor processing structures. Arrangement of sprinkler and water spray protection. ....................... 5
Fig. 3. Outdoor processing structures. Arrangement of sprinkler and water spray protection. ..................... 5

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Fire Protection for Chemical Plants

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FM Global Property Loss Prevention Data Sheets

1.0 SCOPE
This data sheet covers fire and explosion protection of indoor and outdoor areas involving processing
equipment, and supporting structures handling ignitable liquids, flammable gases, and liquefied flammable
gases. It does not apply to ignitable liquid mixing areas only, or to small-scale ignitable liquid occupancies in
conventional manufacturing or utility plants.
1.1 Changes
January 2013. Terminology and guidance related to ignitable liquids has been revised to provide increased
clarity and consistency with FM Globals loss prevention recommendations for ignitable liquid hazards. In
addition, the following significant changes have been made:
A. Changed the name of the data sheet from Fire and Explosion Protection for Flammable Liquid, Flammable
Gas, and Liquefied Flammable Gas Processing Equipment and Supporting Structures to Fire Protection
for Chemical Plants.
B. Reorganized the document to be consistent with other data sheets.
C. Replaced references to flammable and combustible liquids with ignitable liquids throughout the
document.
2.0 LOSS PREVENTION RECOMMENDATIONS
2.1 Introduction
Refer to the following data sheets, as applicable, for recommendations on the protection of indoor and outdoor
areas involving processing equipment, and supporting structures handling ignitable liquids, flammable gases,
and liquefied flammable gases:
Data Sheet 7-32, Ignitable Liquid Operations
Data Sheet 7-43, Loss Prevention in Chemical Plants
Data Sheet 7-44, Spacing of Facilities in Outdoor Chemical Plants
Data Sheet 7-45, Instrumentation and Control in Safety Applications
Data Sheet 7-46, Chemical Reactors and Reactions
Data Sheet 7-47, Physical Operations in Chemical Plants
Data Sheet 7-49, Emergency Venting of Vessels
Data Sheet 7-59, Inerting and Purging of Tanks, Process Vessels, and Equipment
Data Sheet 7-95, Compressors
2.2 Construction and Location
2.2.1 Locate process structures in the open with a minimum of enclosure. Ensure any enclosures are of
damage-limiting construction. (See Data Sheet 1-44, Damage-Limiting Construction.)
2.2.2 Separate process structure areas or buildings from other important areas or buildings by at least 100
ft (30 m). For guidance on separation, see Data Sheet 7-43, Loss Prevention in Chemical Plants, under
Plant Layout, and Data Sheet 7-44, Spacing of Facilities in Outdoor Chemical Plants.
2.2.3 Locate equipment (vessels, pumps, etc.) with ignitable liquid holdup at ground level. Provide solid floors
with curbing and drainage rather than open steel grating beneath such equipment when located at upper
levels. This is particularly important for enclosed process structures or partially enclosed process structures
having roofs.
2.2.4 Provide fireproofing rated for at least two hours on the main structural steel and equipment supports
(load-bearing members) for process areas where there is a greater than average explosion hazard or severe
three-dimensional fire hazard. Use fireproofing that is explosion-resistant, weather-resistant when outdoors,
corrosion-resistant as needed, and capable of withstanding direct application of large fire hose streams.
A greater than average explosion hazard exists under any of the following conditions:

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Fire Protection for Chemical Plants

FM Global Property Loss Prevention Data Sheets

7-14
Page 3

A. Processes located inside buildings using ignitable liquids or flammable gases at such temperature that
an escape from the equipment will result in the formation of an explosive concentration sufficient to cause
major explosion damage.
B. Processes located outdoors utilizing large quantities of ignitable liquids or flammable gases at high
temperatures and/or high pressures, where release of flammable vapors can be expected to cause severe
and widespread damage, such as in an unconfined vapor cloud explosion.
C. Processes using equipment of large volume and low strength that must be taken through the explosive
range at periodic intervals for maintenance or operating purposes.
D. Reactions involving any unstable materials.
E. Processes that are subject to frequent explosions, such as some phenolic resin reactions.
2.3 Occupancy
2.3.1 For process and equipment design, adhere to the recommendations in Data Sheet 7-43, Loss
Prevention in Chemical Plants, under Chemical Plant Process Hazards and Process Equipment Design.
2.3.2 Install and arrange ignitable liquid pumping and piping systems in accordance with Data Sheet 7-32,
Ignitable Liquid Operations.
2.3.3 Provide process equipment with block or isolation valves, vents to flare stacks or incinerators (i.e.,
depressurization system), dump or salvage systems, and quench or purging systems to minimize the quantity
of hazardous material released in the event of equipment failure or accident. The exact type, extent, and
arrangement of such protective equipment will depend on the process involved. See Figure 1 for a typical
arrangement.
2.4 Protection
2.4.1 General
2.4.1.1 Indoor Locations
Provide sprinkler or directional water spray protection in accordance with this data sheet where quantities
of ignitable liquids or liquefied flammable gases are sufficient to cause substantial damage in the event of fire.
In general, for indoor locations, these quantities are approximately 200 gal (0.8 m3) for any one container,
or 2000 gal (7.6 m3) in separate containers over a base area of 2500 ft2 (232 m2). Protect indoor locations
handling smaller quantities of ignitable liquids in accordance with Data Sheet 7-32, Ignitable Liquid
Operations.
2.4.1.2 Outdoor Locations
Provide sprinkler or directional water spray protection in accordance with this data sheet where quantities
of ignitable liquids or liquefied flammable gases are sufficient to cause substantial damage in the event of fire.
In general, for outdoor locations, these quantities are approximately 400 to 500 gal (1.5 to 1.9m3) for any
one container, or approximately 4000 to 5000 gal (15.1 to 18.9m3) in separate containers over a base area
of 2500 ft2 (232 m2).
2.4.1.3 Types of Systems
2.4.1.3.1 Use standard FM Approved high-temperature-rated wet pipe automatic sprinklers or water spray
nozzles when the occupancy to be protected is located inside a building. Use deluge or preaction systems
inside if necessary to provide protection against freezing. Do not use dry pipe systems. Automatic sprinklers
and nozzles are not suitable for outdoor protection because of wind effects and delayed actuation, but are
acceptable in open structures having solid decks if noncombustible draft curtains are provided extending down
a minimum of 5 ft (1.5 m) from solid decks.
2.4.1.3.2 Use deluge sprinkler or water spray systems within structures having no walls (with or without roofs)
because of probable delayed action with standard automatic systems. When water spray nozzles are used,
design the system according to Data Sheet 4-1, Fixed Water Spray Systems for Fire Protection. Design
actuating devices so the water control valve will open if the actuating system is ruptured by an explosion
or other accident. In

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Fire Protection for Chemical Plants

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FM Global Property Loss Prevention Data Sheets

Automatic and remote manual valves

Product lines with block valves
Depressurization system
Dump system
Relief valve

To flare stack
burning pit, or
incinerator

Condenser

Rupture
disc
Raw materials
tanks

Column

Knockout tank

Reactor

To user
Product tanks

To user
To dump tank or
burning pit
Fig. 1. Accidental release control systems and valving.

addition to the manual tripping capability at the deluge valve, provide at least one manual remote station,
preferably located in the process control room or process control area. Where system actuation lines are
grouped, protect them against explosion damage.
2.4.1.3.3 Where water spray nozzles are provided, arrange the nozzles to allow for direct impingement of
water on processing equipment and supporting structures in accordance with Data Sheet 4-1N, Fixed Water
Spray Systems for Fire Protection, under Exposure Protection.
2.4.2 Arrangement of Sprinkler and Water Spray Systems
2.4.2.1 Indoor Locations
For processing structures located indoors, provide area protection below all roofs and operating levels,
whether solid or grated. Provide additional protection for any equipment, equipment supports, and structural
steel located more than 15 ft (4.6 m) below any level of area protection where ignitable liquids can accumulate
(Figure 2).
2.4.2.2 Outdoor Locations
For processing structures located outdoors, provide either area protection or directional water spray
protection. Physical arrangement of the processing structure and equipment will determine which type of
protection is more practical. Provide protection at least to a height of 10 ft (3.0 m) above normal ignitable liquid
levels within the vessels, or up to 30 ft (9.1 m) above the height where substantial quantities of ignitable

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Fire Protection for Chemical Plants

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FM Global Property Loss Prevention Data Sheets

A.S.
15'
(4.6m)
A.S. grate
15'
(4.6m)

Ceiling

0.30
(12mm/min.)

0.15
(6mm/min.)
45'
(12mm/min.) (13.7m)
0.30

Page 5

A.S.
15'
(4.6m)
A.S. grate
15'
(4.6m)

Ceiling

0.30
(12mm/min.)

0.15
(6mm/min.)
(12mm/min.)
0.30

50'
(15.2m)

A.S. grate
A.S. grate
15'
(4.6m)

15'
(4.6m)

20'
(6.1m)

5'
(1.5m)

Maximum height exceeds 15 ft (4.6 m). Therefore,

additional protection required for equipment,
equipment supports, and structural steel.

Fig. 2. Indoor processing structures. Arrangement of sprinkler and water spray protection.

liquids may accumulate, whichever is higher (Figure 3). Ignitable liquid holdup in trays of distillation columns
should not be considered accumulations of substantial quantities of ignitable liquids.

Fig. 3. Outdoor processing structures. Arrangement of sprinkler and water spray protection.

For area protection, follow the recommended protection arrangement for processing structures located
indoors, subject to the aforementioned height limitation (Section 2.4.2.1). Provide area protection directly
beneath any solid operating level or roof. Area protection will protect a maximum of 15 ft (4.6 m) beneath any
solid operating level.
2.4.2.3 Provide protection below any obstruction to water distribution that exceeds 3 ft (0.9 m) in width or
diameter and 10 ft2 (0.9 m2) in area. Important structural members or equipment below obstructions of smaller
size may need additional protection against flame impingement. Unless completely fireproofed, protection
is needed inside the skirts of columns or similar self-supporting vessels.

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7-14

Fire Protection for Chemical Plants

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FM Global Property Loss Prevention Data Sheets

2.4.2.4 Protect pipe racks within 20 ft (6.1 m) of process structures. Pipe racks further than 20 ft (6.1 m)
from a process structure may still need protection in the form of sprinklers, water spray, two-hour-rated
fireproofing, or a combination thereof depending on the loss potential.
2.4.2.5 Limit sprinkler spacing to a maximum of 100 ft2 (9.2 m2) per sprinkler. Arrange water spray nozzles
according to Section 2.4.1.3.3.
2.4.2.6 Where main structural steel and equipment supports (load-bearing members) are fireproofed with a
material having a fire resistance rating of two hours or more (refer to Section 2.2.4), additional water
protection is unnecessary for these supports.
2.4.3 Protection of Piping, Valves and Fittings Against Damage from Explosions
2.4.3.1 Locate risers in areas cut off by pressure-resistant walls or shielded by structural columns.
2.4.3.2 Locate feed and cross mains away from reactors or pressure vessels (e.g., in the aisles or to the
sides of reactors or pressure vessels, but never directly above this equipment).
2.4.3.3 Bury and loop water supply mains to hazardous process areas. Provide divisional valves so any breaks
due to explosion damage can be isolated.
2.4.3.4 Ensure all piping over 2 in. (51 mm) is welded or has welded flanged fittings. Welding should conform
to the ANSI/ASME standard for pressure piping, B31.1 Power Piping. Welded flanged fittings should conform
to ANSI/ASME Standard B16.9 Factory-Made Wrought Steel Buttwelding Fittings or ANSI/ASME Standard
B16.25, Buttwelding Ends. Prohibit welding in an occupied structure; however, welded subassemblies may be
prepared outside the area and assembled (flanged) within the area. Piping 2 in. (51 mm) or smaller may
be welded; otherwise, use malleable iron-on-steel fittings of 150 lb steam rating (300 lb W.O.G. rating). These
fittings should conform to ANSI/ASME Standard B16.3, Malleable Iron Threaded Fittings, 150 and 300 lb;
or ANSI/ASME Standard B16.5, Steel Pipe Flanges and Flanged Fittings. Do not use flexible couplings.
2.4.3.5 Ensure piping is supported from the building or structural framework. However, outdoor piping may
be attached to self-supporting process equipment.
2.4.3.6 Provide a readily accessible manual shutoff valve for each system within the processing structure
located indoors or outdoors. Locate all manual shutoff valves and automatic sprinkler control valves (alarm
check, deluge, etc.) at least 50 ft (15.2 m) from the building or structures.
2.4.4 Water Supply
2.4.4.1 Density
2.4.4.1.1 Indoor Locations
For area protection of processing structures located indoors, provide the following densities, as illustrated
in Figure 2.
A. 0.3 gpm/ft2 (12 mm/min) at each protection level above a solid floor or level.
B. 0.3 gpm/ft2 (12 mm/min) under any solid intermediate level or roof.
C. 0.15 gpm/ft2 (6 mm/min) under all other levels.
2.4.4.1.2 Outdoor Locations
For area protection of processing structures located outdoors, provide 0.3 gpm/ft2 (12 mm/min) per required
protection level (Figure 3).
2.4.1.3 Water Spray Protection For directional water spray protection, provide densities according to Data
Sheet 4-1N, Fixed Water Spray Systems for Fire Protection.

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Fire Protection for Chemical Plants

FM Global Property Loss Prevention Data Sheets

7-14
Page 7

2.4.4.2 Demand
2.4.2.1 Outdoor Locations
For processing facilities located outdoors, determine the design operating area based on simultaneous
operation of all additional protection systems within 100 ft (30.5 m) of the first involved deluge or local
water-spray system.
2.4.2.2 Indoor Locations
For processing facilities located indoors, assume all sprinklers will open within the building for ground floor
areas up to 10,000 ft2 (929 m2). If deluge sprinkler or water spray systems are provided, assume all systems
will operate.
2.4.4.2.3 In addition to the above water requirements, include any hose streams and/or monitor nozzles likely
to be used to determine the total water demand.
2.4.4.3 Duration
Provide a water supply capable of maintaining discharge and pressure requirements until the ignitable liquid
flow can be shut off and the area drained, or the ignitable liquid is consumed. Requirements will vary with
each installation. Provide a minimum duration of two hours.
2.4.5 Drainage
Provide processing areas with emergency drainage to an acceptable location. For guidance, refer to Data
Sheet 7-83, Drainage and Containment Systems for Ignitable Liquids, and Data Sheet 4-1N, Fixed Water
Spray Systems for Fire Protection. Each drained area should not exceed 5000 ft2 (465 m2). The drainage
system should be capable of handling all anticipated sprinkler and/or water spray discharge and hose stream
water.
2.5 Equipment and Processes
2.5.1 Provide and arrange instrumentation in accordance with the recommendations in Data Sheet 7-43,
Loss Prevention in Chemical Plants.
2.6 Operation and Maintenance
2.6.1 Provide inspection and maintenance procedures, operator training, and emergency procedures in
accordance with the recommendations in Data Sheet 7-43, Loss Prevention in Chemical Plants.
3.0 SUPPORT FOR RECOMMENDATIONS
3.1 General
Processing facilities where ignitable liquids, flammable gases, and liquefied flammable gases are used in
quantity can be protected from fire with insulation and fixed protection such as automatic sprinklers, water
spray, and monitor nozzles. Explosion damage can be minimized by using open construction or damagelimiting construction with adequate spacing or separation.
Fires within such facilities may be open tank fires, spray fires from liquids under pressure, gas fires from
escaping gases or vaporizing liquefied flammable gases, or combinations of these. Liquids escaping from
equipment will gravitate to lower levels, exposing other equipment in the structure; multilevel fires of all types
are possible. Equipment explosions can also occur due to fire exposure.
Explosions within such facilities may also occur due to runaway chemical reactions with or without an ensuing
fire, or from escaping gas or vapor, particularly within an enclosed area. Unconfined vapor cloud explosions
are also possible in congested open process facilities where large quantities of ignitable liquid are handled
at elevated temperatures and pressures. For more detailed information on vapor cloud explosions, see Data
Sheet 7-42, Evaluating Vapor Cloud Explosions Using a Flame Acceleration Method.
Water will not, in general, extinguish fires involving flammable gases, liquefied flammable gases, and ignitable
liquids having flash points below 200F (93C). Automatic sprinklers and/or water spray will, however, provide
a combination of general area cooling and actual wetting of equipment and structures, thereby preventing

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Fire Protection for Chemical Plants

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FM Global Property Loss Prevention Data Sheets

weakening of metal by overheating. The cooling and wetting also will prevent load displacement caused by
thermal expansion of structural members and rupture of process tanks and piping.
3.2 Test Data
FM Global conducted a fire test program to evaluate the effectiveness of foam-water sprinkler protection,
standard sprinkler protection, and combinations of both for a multilevel ignitable liquid process steel structure
40 ft (12.2 m) high.
Two basic types of fire tests using heptane as a fuel source were conducted: two-dimensional floor spill fires
and three-dimensional spill fires involving a fuel spill at an upper level of the process structure.
Three important findings of the test program were:
1. three-dimensional (i.e., upper open level) spill fires create a more severe fire exposure than floor spill
fires.
2. foam-water sprinklers at a 0.16 gal/min/ft2 (6.5 mm/min) density can help control a floor spill fire quickly,
but are not very effective in reducing exposure from a three-dimensional (upper open level) spill fire.
3. foam-water sprinklers at a 0.16 gal/min/ft2 (6.5 mm/min) density and/or standard sprinklers installed
in accordance with these guidelines can protect process structures against floor spill fires.
The results of these findings indicate that fire protection guidelines for process structures should emphasize
locating equipment with ignitable liquid holdup at ground level and providing solid floors with curbing and
drainage rather than open steel grating beneath such equipment when located at upper levels.
4.0 REFERENCES
4.1 FM Global
Data
Data
Data
Data
Data
Data
Data
Data
Data
Data
Data
Data
Data

Sheet
Sheet
Sheet
Sheet
Sheet
Sheet
Sheet
Sheet
Sheet
Sheet
Sheet
Sheet
Sheet

1-44, Damage-Limiting Construction

4-1N, Fixed Water Spray Systems for Fire Protection
7-32, Ignitable Liquid Operations
7-42, Evaluating Vapor Cloud Explosions Using a Flame Acceleration Method
7-43, Loss Prevention in Chemical Plants
7-44, Spacing of Facilities in Outdoor Chemical Plants
7-45, Instrumentation and Control in Safety Applicationsmed
7-46, Chemical Reactors and Reactions
7-47, Physical Operations in Chemical Plants
7-49, Emergency Venting of Vessels
7-59, Inerting and Purging of Tanks, Process Vessels, and Equipment
7-83, Drainage Systems for Ignitable Liquids
7-95, Compressors

4.2 Others
American Society of Mechanical Engineers (ASME). Malleable Iron Threaded Fittings. ANSI/ASME B16.3.
American Society of Mechanical Engineers (ASME). Buttwelding Ends. ANSI/ASME B16.25.
American Society of Mechanical Engineers (ASME). Factory-Made Wrought Steel Buttwelding Fittings.
ANSI/ASME B16.9.
American Society of Mechanical Engineers (ASME). Power Piping. ANSI/ASME B31.1.
American Society of Mechanical Engineers (ASME). Steel Pipe Flanges and Flanged Fittings. ANSI/ASME
B16.5.
APPENDIX A GLOSSARY OF TERMS
FM Approved: References to FM Approved in this data sheet mean a product or service has satisfied the
criteria for FM Approval. Refer to the Approval Guide, an online resource of FM Approvals, for a complete
listing of products and services that are FM Approved.

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Page 9

Ignitable Liquid: Any liquid or liquid mixture that will burn. A liquid will burn if it has a measurable fire point.
Ignitable liquids include flammable liquids, combustible liquids, inflammable liquids, or any other term for
a liquid that will burn.
APPENDIX B DOCUMENT REVISION HISTORY
January 2013. Terminology and guidance related to ignitable liquids has been revised to provide increased
clarity and consistency with FM Globals loss prevention recommendations for ignitable liquid hazards. In
addition, the following significant changes have been made:
A. Changed the name of the data sheet from Fire and Explosion Protection for Flammable Liquid, Flammable
Gas, and Liquefied Flammable Gas Processing Equipment and Supporting Structures to Fire Protection
for Chemical Plants.
B. Reorganized the document to be consistent with other data sheets.
C. Replaced references to flammable and combustible liquids with ignitable liquids throughout the
document.
May 2004. References to various applicable ANSI/ASME standards were updated.
January 2000. This revision of the document has been reorganized to provide a consistent format.
APPENDIX C SUPPLEMENTAL INFORMATION
Processing facilities, particularly within chemical plants, involve structures that vary widely in shape and size.
Some have neither walls nor roofs, but often have high elevations and small floor areas. Work floors of solid
construction or open-grating construction may be located at various levels. Such floors may be incomplete
or penetrated by stairs, elevator shafts, piping and equipment. Tanks, reactors, condensers, stills, and pipe
racks may be arranged irregularly throughout or adjoining the structures.
Typical of such facilities are petrochemical plants, pharmaceutical plants, solvent extraction plants, agricultural
chemical plants, and plastics manufacturing plants.

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