Report on

‘Processes at ONGC and

available firefighting
facilities and equipment’

Submitted under Guidance of

Mr. ALOK KUMAR

By

Deepak Kumar Gaurav Kumar

Pawan Singh Bisht Pawan Yadav

Saurabh Choubey Shubham Sinha

Sumit Mandal

Dept. of Safety and fire Engineering

School of Engineering
CUSAT, Kochi 682022

Certificate

1
This is to certify that the training
report titled “Processes at
ONGC and available firefighting facilities and
equipment” is being submitted by below listed
student, is in line with requirements for the award
of completion of training certificate for the training
at IPSHEM, ONGC GOA campus during the two-
week period from 16th August – 29th August in
the academic year 2020-21.
List of Students MR. Alok Kumar
Deepak Kumar 20618028
Gaurav Kumar 20618031 Manager, Fire Services,
Pawan Singh Bisht 20618047 ONGC
Pawan Yadav 20618048
Saurabh Chaubey
20618056
Shubham Sinha
20618058
Sumit Mandal 20618062
A Adhithya 20618001
Abdul Razak P S
20618003
Ashish A S 20618019
Beebi Nuamana Khaleel P P
20618026
K S Sreehari 20618038
Sneha Joseph 20618059

2
 Declaration

We hereby declare that the work being presented

for the Training project report titled “Processes at
ONGC and available firefighting facilities and
equipment” is an authentic record of work which
had been carried out at IPSHEM, ONGC GOA,
Campus under the guidance of Mr. Alok Kumar
(Manager, Fire services) by the training group
named below, from Cochin university of science
and technology.
List of Students
Deepak Kumar 20618028
Gaurav Kumar 20618031
Pawan Singh Bisht 20618047
Pawan Yadav 20618048
Saurabh Chaubey
20618056
Shubham Sinha
20618058
Sumit Mandal 20618062
A Adhithya 20618001
Abdul Razak P S
20618003
Ashish A S 20618019
Beebi Nuamana Khaleel P P
20618026
K S Sreehari 20618038
Sneha Joseph 20618059

3
 Table of Contents

Sr. Contents Page

No. No.

1 Cover Page 1
2 Certificate 2
3 Declaration 3
4 Acknowledgments 5
5 Abstract 6
6 About ONGC 7
7 Processes and Associated 9
Hazards in ONGC
8 Fire-fighting facilities and 27
methodologies adopted in ONGC
9 Recommendation as per OISD 47
STD 189
10 Conclusion 51

4
 Acknowledgements

We would like to thank first to the Almighty God for

bestowing us with conscience to gain knowledge and use it
for benevolent cause to the best of our ability. Then we thank
our parents for raising us to be who we are today and making
us capable of being instrumental in progress of humanity.
Now for this piece of study presently at hand we would whole
heartedly like to Alok Kumar sir at IPSHEM. Covid has been a
tough period for entire humanity and academia is one of the
most suffered sectors. Owing to the prevailing situation, the
online mode of training was a novel experience and a new
learning curve for all. Despite all the restriction Alok sir put
his most indelible effort to impart the quality of knowledge.
The project is amalgamation of our efforts and his continuous
guidance and support. Utilize the best possible tools and tech
he made sure that no short comings are left uncovered. For
all his genuine and tireless efforts to deliver to us the quality
training we extend our gratitude to him.

5
 Abstract
The upstream industry is arguably the most complex of
all the oil and gas business sectors. Since it is highly
capital-intensive and highly risky business by its nature,
early Hazard Identification and their mitigation becomes
very crucial.
This project is an attempt to recognize major processes
happening at ONGC India’s largest PSU and accident
hazards & their control measures as taken by the
organization. Major accident hazards are those that have
the potential to cause multiple fatalities, ecological
imbalance and may necessitate the evacuation of
facilities. The potential for escalation of the initial events
is primarily determined by the design of the facility and
the protection systems provided.
The project puts forth a comprehensive analysis of all the
norms and methodologies at place in ONGC through a
comparative study with the adopted policies and
requirements as per the Standard (OISD 189).

6
 ABOUT ONGC

Maharatna ONGC is the largest crude oil and natural gas

Company in India, contributing around 71 per cent to Indian
domestic production. Crude oil is the raw material used by
downstream companies like IOC, BPCL, HPCL and MRPL (Last

7
two are subsidiaries of ONGC) to produce petroleum products
like Petrol, Diesel, Kerosene, Naphtha, and Cooking Gas LPG.
Oil and Natural Gas Corporation Limited (ONGC) is a global
energy holding company, engaged in the oil exploration,
development, and production of crude oil and natural gas. Its
segments include Exploration & Production (E&P), and
Refining.
ONGC's on-going upstream exploratory efforts are an
important segment of its core E&P Business in India with the
responsibility of finding and accreting oil and gas reserves. It
has three facets of hydrocarbon exploration activities viz.
Deep Water, Shallow Water, and Onshore exploration
activities.
ONGC ranked 4th in India in 2021 ranking of Fortune Global
500 list.
ONGC Group of Companies comprises of:

Source: ongc website

8
Processes and associated
Hazards in ONGC

9
A Hazard is a situation that poses a level of threat to Life,
Health, Property or Environment. Most hazards are dormant
or potential, with only a theoretical risk of harm; however,
once a hazard becomes "active", it can create an emergency
situation. Hazard and possibility interact together to create
risk.
Oil & Gas continues to be the major source of energy and
dependency has grown too high since majority of energy
needs are met by this sector. This has necessitated the
adoption of new technologies in exploration, refining &
storage of the hydrocarbon in Oil & Gas Industry.
Thus, a lot of technological improvements have taken place
both in upstream & downstream sectors of Oil & Gas to
enhance oil recoveries in upstream and make environment
friendly products in downstream.
ONGC is committed to the idea that all the incidents
(including fire) are preventable; hence every fire incident can
be classified by the place of work of its occurrence. In ONGC,
working areas can be classified as: -
1. Exploration
a) Geophysical drill site on land
b) Seismic vessel at offshore

2. Drilling
a) Drill site on land
b) Work Over Rig on land
c) Jack-up drilling rig at Offshore
d) Drill Ship/Floater at Offshore
e) Workover Rig at Offshore

10
3. Production
a) Well on land
b) Well Platform at Offshore
c) Well Head Installation (WHI) on land
d) Early Production System (EPS)
e) Group Gathering Station (GGS)
f) Production Platform – Unmanned

g) Production Platform – Manned

h) Gas Collecting Station (GCS) – Onshore
i) Gas Compressor Station
j) Central Tank Farm (CTF) area
k) LPG Plant
l) Process Plant
m) Processing Complex
n) Effluent Treatment Plant (ETP)
o) Central Processing Facility (CPF)

4. Transportation
a) Oil Pipeline on Land
b) Gas Pipeline on Land
d) Pumping Station of Pipeline on Land
e) Submarine Pipeline

11
f) Rail and Road Loading Gantries
g) Land Fall Points
h) Offshore Support Vessel (OSV) & Multipurpose Support
Vessel (MSV)

5. General Services
i. Workshops
ii. Laboratories
iii. Electrical Substations
iv. Stock Yards
v. Central Stores
vi. Explosive Magazines
vii. Multi-storeyed Office Buildings
viii. Residential Colonies, etc.
The major hazards associated with the oil industry are fire,
explosion, sudden pressure release and toxic release. Of
these, fire is the most common, but explosion is particularly
significant in terms of fatality and losses. ONGC has been
engaged in oil and natural gas exploration and production
since its inception. Since exploration, production, refining and
marketing of hydrocarbons are the multidisciplinary task and
are spread on land and sea, hence one has to be extremely
cautious and safe in each operation being performed.
Therefore, ONGC encounters all types of common fire
hazards known in the industrial operations, besides some
special types of fire hazards specific to oil industry only.
Some of the major hazards are listed below:

12
Activity Hazards/ Risk Controls

Tested BOP
Drilling Mud System
Drilling / Kick / Blowout Cement Integrity test
Testing/
Well Control System
Completion
/ Operational Drills
Fluid weight control
Surface Line Test
Analysis of sampling during
Cementing
Communication System
Training & Competency
Loss Prevention Program
Well Shut-in & Control Procedures

13
 Production/ Active Secondary Containment
ProcessingHazards/
Activity Causes PassiveControls
Secondary
Storage/ Risks Containment
Spillage of
transportati harmful/Gas from Gas
Sealing Test
Detection
Deterioration of System (fixed &
on of Well Synthetic /Bulk
Stored Mud, Slip JointPortable)
Certification
fluid materials to the
Toxic/
environmentGas from
Monitoringor ofConfined Space
Process Control
OR Flammable
present in confined Entry Permit
Equipment
Gas Release
Handling spaces
Drilling / Such as Buddy work in
Fuels for H2S,CH4, H2, Spill Kit
confined
Completio
EquipmentCO, etc. Overfill Protection System
n Loss of Choke Manifold
Culverting/ Drainage
atmospheric Tests System
separator hydraulic
Seal Sumps & Collection System

Operational Failure Poor boy Degasser

Leakage on valves, PPEs/ BAs
Flanges etc.
Scavenging
Chemicals

Activity Hazard/ Effects / Controls

Risk
Consequence
Fire/ Smoke Detectors
People Injury Gas Detectors
(fixed & Portable)
Damage to BOP
environment
Drillilng/ Fire/ Diverter System

14
Completion/ Explosion Fire Fighting Equipment
Production Training & Mock Drills
Financial loss SOP /JSA/ MOC/ PTW
(downtime,
Fire Alarms/ PPEs/ BAs
asset &
Reputation loss Identification of Ignition
Sources
Emergency Shower
First Aid Facilities
Emergency Rescue Plan

SI. Type of Area Portable Fire Extinguisher

No.
1. Derrick floor 2 nos. 10kg DCP type extinguisher
2. Main Engine Area 1 no. 10 kg DCP type extinguisher
for each engine
3. Electrical motor/pumps 1no. 10kg DCP type extinguisher
for water circulation for
mud pump

15
 4. Mud gunning pump 1no. 10kg DCP type extinguisher
5. Electrical Control Room 1no. 6.8 kg CO2 type extinguisher
for each unit
6. Mud mixing tank area 1no. 10kg DCP type extinguisher
7. Diesel storage area 1no. 50 lit mechanical foam
1no. 50kg DCP type extinguisher
2nos. 10kg DCP type extinguisher
2nos. sand bucket or ½ sand drum
with spade
8. Lube Storage Area 1no. 10kg DCP type extinguisher
1no. sand bucket
9. Air Compressor area 1no. 10kg DCP type extinguisher
10. Fire pump area 1no. 10kg DCP type extinguisher
11. Near Dill in charge One fire extinguisher/shed with 3
Office nos. 10kg DCP type extinguisher
and 2 sand buckets.
12. Fire bell near bunk 1no. 10kg DCP type extinguisher
house

Activity Hazard Causes Controls

/Risk
Overloaded Defensive Driving
Vehicle Trained Drivers
Road Road
Transportation of Accident Mandatory Seat belt
Workers, Drilling
Driver Fatigue Speed limit as
fluid, equipment
Prescribed

16
etc. (Collision of Operational No mobile phones
Vehicles, Failure while driving
Fuel Spillage
Night Journey
etc.)
Management plan
Equipment
Failure Vehicle
Maintenance &
Periodic Inspection
Vehicle Road
Worthiness
Certificate

Activity Hazard/ Risk Effects/ Controls

Consequences
Loss of control / Pilot Training
crash of
Fire / Explosion
helicopter due to:

17
 – Extreme Pilot Helideck
weather Operational
Environmental
– Helicopter Experience
/ Damage
equipmen
Helicopte t failure Airworthiness
r – Pilot error Structure
of Helicopter
operatio – Obstructio Failure
ns n in
landing /
Competent
takeoff People Injury
Personnel –
Path
– Helideck Crew/ HLO
structure Loss of Rig
failure
– Ditching HUET
Downtime

Fire Fighting
Loss of Site Training

Activity Hazards Controls

18
 ❖ Occupational Rig Movement Plan
hazards such as:

Defensive Driving
a. Dropped Object
b. Fall of person from Trained Drivers
monkey board.
c. Electrocution
d. Personnel getting New Location Planned
Rig Movement
entangled in lines & Inspect Pre-
Onshore during raising of movement
mast
e. Being struck by
(Drilling / swinging objects. Maintain safe
Completion) f. Chemical Hazard due distance from
to mud splash overhead lines
g. Swinging block/ pipe
hitting the derrick
h. Pinch points at pipe, Selection of vehicles,
elevator links, & slip cranes and lifting
handles. gear (such as wire
i. Road Accident
rope slings, lifting
eye, lifting rope for
mast etc.).

Use of body harness /

safety belt &
Specified PPEs

19
 ❖ In case of offshore
rigs, hazards
include:
Working at height –
a. Change in weather use of fall prevention
conditions – wind devices, man
speed, current, wave overboard
height Seabed precautions for
/conditions/ stability offshore operations.
b. Punch through (in
case of jack up rigs)
c. Water depth Shut down of wells on
d. Mooring / station platform (offshore)
keeping systems during rig move &
e. Other nearby assets proper preloading
Rig Movement such as platform guidelines to be
structure, piping at
Offshore adhered to.
platform, pipelines at
seabed and flowing
wells at platform etc.
(Drilling / f. Dynamic loading Pre move meetings
Completion) g. Towing operation –
fitness of tug boat
and anchor handling Competent personnel
equipment, vessel
collision
h. Lack of marine Inspection of Tug
competence Boats and their
i. Inadequate towing lines
procedures
j. Coordination failure –
communication Towing wires
failure,
accountability not Designed as per load
defined of rig.

20
Activit Hazards Controls
y
Installation, Maintenance &
Inspection of well control
equipment.

Adherence to well control policy /

Uncontrolled flow of procedures.
well fluid / blowout

Competent personnel

CO Hazards from P
erforation during Use of specified PPEs
Perfora P&A Operations
tion
Switching off wireless
communication equipment
(Drillin Occupational
g/ hazards during the Electrical Isolation & Protection
Comple handling of for lightening
tion) explosives due to :-
& - Uncontrolled
Proper Gun Design
Plug - Detonation
and
abando - Surface
Perforating operations involving
nment Detonation electrical detonators should not
- Explosion be carried out during electrical or
static-generating dust storms

21
 Adding an oxidizer (e.g., perchlor
ate) inside the gun system is
to reduce CO a maximum of 25%.

Activity Hazards Controls

Over pressure Proper Separator design
Production Under pressure Calibration of safety Devices
Well fluid Liquid overflow Ventilation and exhaust system
processing &
Fire Combustible HC gas Detector
separation
Low liquid level / Make up Gas system
gas blowby
Corrosion of SOP/ JSA/ PTW
pipelines
Loss of containment Integrity Management System
due to equipment
ESD / Blowdown System
failure
Proper Layout
Fire Protection System
Emergency Response
Preparedness

Activity Hazards Controls

Loss of containment due Equipment Design as per
to : OISD-111
-High temperature PSV

Heating of -Over pressure Level Controller valve

well fluid -Corrosion Explosion proof fire

22
 chamber.
(Production) Direct ignition sources Remote ignition system
and excess fuel in firing
PTW / JSA / SOP
chamber in case of fired
component: Flame in the firing
chamber is monitored by
a. Explosion
BSL or TSL sensor. Flame
b. Backfire arrestor in natural draft
burner.

Activity Hazards Controls

Proper Tank Design
High- Level Alarm
Breather valve and vent
Loss of containment Level Gauges
due to :
Pressure Gauges
– Over Flow
Bonding & Grounding
– Corrosion
Crude Flame arrestor on tanks
Storage – Overpressure
Corrosion Protection System
Periodic Inspection
(Production)
HC and fire detection on
tanks
Fire / Explosion Confined space entry
– Boil over procedures – work permit
system.
– Slop over
Competent personnel
– Pool fire
Tank Farm Layout as Per

23
 OISD- 118
Fire Protection System
Dikes & Bunds

Activity Hazards Controls

Radioactive substances are Certification &
present in:- authorization for
Handling
equipment onboard
Radioactive 1. X-Ray Machines at
Substance the entrance Only qualified & trained
person
2. Wireline
operations Radioactivity control
(Drilling /
sheet
Testing/ 3. Logging operations
Production) Radioactive load checklist
4. Hydraulic
Fracturing NORM management
(Radioactive system
tracers)
Pre-operation meeting
5. NORM while
drilling Safe Disposal of
Radioactive substances
Specific place for
Radioactive sub. Storage
& restricted access
SOP/ JSA/ PTW
Contingency Plan & ERP

24
Activity Hazards Controls

Over pressure Proper Compressor Design

(suction)
Over pressure Protection against reverse
(discharge) rotation for rotary /centrifugal
compressor.
Fire / Explosion Purging before start up
Gas Excess temperature Back pressure Protection from
compression flare / vent line
Loss of containment Safe routing of leaked gases
(Production) due to: from sealing system.
– Overpressure Alarms and trips to detect seal
failures
– Corrosion
Noise hazards - display warning
– Seal Failure
signs
– Mechanical
Noise hazards - display warning
damage
signs
– Failure of
Training & Competency
safety systems
SOP/ JSA/ PTW
ERP
ESD / blow down system

Activity Hazards Controls

Fire Proper blow down system
design
Blowdown/
Depressurizatio Explosion Kock Out Drum (KOD)
n
Loss of Remote Ignition of Flare Stack
containment due
Purging should be done before

25
(Production) to : start up
– Over Sufficient Stack Height
pressure
Competent Personnel
– Carryover of
SOP
liquid with
gas.
– Failure due to PTW
corrosion
– Mechanical
JSA
failure

Activity Hazards / Causes Control

Risk
Loss of Improper well Ensure kick tolerance
Containme servicing
Ensure two
nt\ program
independent barriers
Uncontrolle
Intrinsically Safe
d flow of
Electrical Equipment
well fluid
Well control Adherence to well
(Blowout)
Well equipment control policy
Servicing failure
Failure to fill the Periodic well control
well during drills
tripping.
Job Safety Analysis.
Fire/ Casing integrity competent personnel
Explosion failure
Failure to fill the Well-killing Procedures
well during
Safety briefing
tripping.

26
27
Fire Fighting facilities and
methodologies adopted in
ONGC

28
Fire Protection Philosophy
The Fire Protection Philosophy in oil and gas industry is based
on Fire safety, Loss Prevention and Control. It considers that
in the hydrocarbon industry, the risk of fire is omnipresent at
all levels of operational activities like exploration, drilling,
production, processing and distribution, critical operations
requirement and large inventories stored at facilities. A fire in
one part of these operational areas can endanger other
part/section of the area, if not controlled or extinguished as
quickly as possible to minimize the loss of life and property
and prevent further spread of fire.
Considering the above philosophy, the basic fire protection
requirement depends on various factors like area of
operations, size of storage tanks, layout of facilities like GGS,
CTF, Oil & Gas Processing installation, pipeline installation,
disposal system of blow down, drainage from equipment
handling petroleum product, pressure & temperature
conditions in the process, terrain, etc. Material of
construction for infrastructure facilities shall conform to
various statutory regulations like National Building Code
(NBC), Oil Industry Safety Directorate (OISD), National Fire
Protection Association (NFPA), American Petroleum Institute
(API), etc.
Depending on the nature and size of installation and
risks involved, appropriate fire protection facilities out
of following shall be provided
i) Water Spray System.
ii) Foam System.
iii) Hydrants and Monitors.
iv) Fire Extinguishers.
v) Portable/mobile firefighting equipment

29
vi) Clean Agent system
Design Criteria for Fire Protection System
AS per OISD 189 the following shall be the design criteria for
a fire protection system
 The fire protection facilities shall be designed considering
that city fire water supply is not available close to the
installation.

 The fire protection facilities at drilling rig, workover rig and

production installations like WHI, QPS and EPS shall be
designed to initiate an immediate firefighting operation so as
to prevent escalation into a major emergency.

 Water spray system shall be provided for GCS and GCP.

 A single largest fire risk shall be considered for providing

firefighting facilities.

 Installations storing Class A and B petroleum in above

ground tanks shall be provided with fixed water spray
system, for the following conditions: -

Aggregate above ground storage of Class A and B petroleum

is more than 1000
KL.
ii) Diameter of floating or fixed roof tanks storing Class A
petroleum is more than 9 m.

30
Further, fixed water spray system shall be provided on all the
tanks, where inter
distances between tanks in dyke and/or within dykes are not
meeting the
requirements of OISD-STD-118.
 Fixed foam system or Semi-fixed foam system shall be
provided for all tanks (floating roof or fixed roof) and storing
Class A or Class B petroleum.

 Water cum foam monitors/foam hose streams shall be

considered for fighting fires in dyke area and spills.

 In an ETP plant, all the areas susceptible to fire hazards

shall be covered by fixed firefighting system with water cum
foam monitors and hydrants.

 Fire water system shall be designed for a minimum

pressure of 7 kg/cm2 at the most hydraulically remotest point
of application.

 Hydraulically remotest hydrant or monitor is the one

located at farthest distance from the pump or located highest
on the superstructure or located at the end of a poorly sized
branch line, and encounters maximum pressure drop, at the
designed flow rate at that point.

Fire Station

31
A fire station is the basic operational Centre of ONGC Fire
Service in the Asset / Plant/Installation. In major Work Centers
the main, centrally located fire station is designated as
“Main Fire Station” for coordinating the activities of other
fire stations. Main Fire Station has minimum two authorized
manned fire tenders for initial emergency response. All other
fire stations in the Work Centers are called as “Sub-Fire
Station”. In smaller Work Centers sub – Fire Stations can
perform the role of the Main Fire Station of the Work Centre.
Functions of Fire Station
(a) Co-ordinate all activities in connection with fire safety,
fire protection and firefighting operations within the
operational jurisdiction.
(b) To respond to any emergency call.
(c) To organize maintenance of firefighting equipment
available in the field and also which are available at the Fire
Station itself.
(d) Checking and testing of fixed firefighting equipment.
(e) To perform standby duties during hot jobs, hot oil
circulation, well stimulation, Helicopter landing and take-off
etc.
(f) Conducting onsite training programmes, mock drills etc.
(g) Provide mutual aid assistance to sister industries
and assist civil administration in firefighting & rescue
operations, when so required.

FIRE CONTROL ROOM

AS per OISD 163 “Control Room” is a protective enclosure
equipped with control & communication services and

32
environmental treatment necessary for proper functioning of
the Hydrocarbon Processing and Handling Installation. The
control room could either be blast-resistant or non-blast
resistant as applicable to the type of installation”
 Functions
 To attend and respond all emergency situations calls (like-
Gas leakage, blow out situation, Fire call, disaster)
 Keep a record of all the employees attendance.
 Maintain records of Daily activities in situ of fire station
 Maintain a log book and location tracking (GPS) of every fire
tender and its movement
 Conduct Mock drill, one day training programmers to ONGC
as well as people in the vicinity of installations.

Communication
A. Line Communication: -

I. A telephone only with incoming calls facility for receiving

fire calls in the fire station/control room.

II. Another telephone for communication with outside

agencies like local civil/police/fire authorities, mutual support
stations, etc.

III. Intercom / hotline connection for intra communication

within the Asset/Installation/Work Centre etc.

B. Wireless Communication:

33
I. All Main / Sub Fire Stations are equipped with VHF sets of
required capacity as Base Station to communicate among
themselves as well as with the fire appliances of the station.
II. All fire tenders/fire vehicles are fitted with VHF sets of
sufficient capacity as Mobile Stations to be in constant
contact with their respective fire stations.

III. Each fire vehicle is are equipped with 4 walkie – talkie sets
of 5 watt capacity for use by the crew on firefighting duty
away from the tender.

34
FIRE TENDERS
Specifications for fabricating a fire vehicle commonly used in
petroleum industry are given here
1. FOAM TENDER

The Foam Tender including all accessories should be

designed and manufactured as per relevant Indian Standards
and Tariff Advisory Committee (TAC) ’s requirements
wherever applicable and should be as per sound engineering
practice. The specifications mentioned hereunder lays down
the minimum requirements regarding material, design,
construction, workmanship and finish, accessories and
acceptance tests of foam tender. All the equipment and
accessories should be fixed on the appliance in a compact
and neat manner and should be so placed that each part is
easily and readily accessible for use and maintenance.

The centre of gravity should be kept as low as possible.

1.1 CHASSIS
(i) Foam tender should be fabricated and built on suitable
chassis of payload 10 tones or payload 16.8 tones or
equivalent to match engine and pump characteristics.
(ii) The Foam Tender should have power steering.
(iii) Drag hook or eye of adequate strength and design should
be provided at the front and rear of the chassis.
(iv) All wiring should be properly fixed in position and should
be protected against heat, oil and physical damage.
Wherever possible wiring should pass through PVC sleeves.
(v) All important electrical circuits should have separate fuses
suitably indicated and grouped in a common fuse box located
in an easily accessible position. Provision should be made for
a minimum four (4) spare fuses in the fuse box.
(vi) Engine: The vehicle engine should be diesel driven
preferably with synchromesh 5 forward and 1 reverse speeds
gearbox. Engine should be equipped with a complete starting

35
system of 24 V type. An alternator and rectifier capable of
delivering a minimum of 50 A at 24 V should be provided.
(vii) Batteries: Ordinary lead acid batteries. Master isolation
switch should be provided in dashboard panel.
(viii) Radio suppression of the electrical system, which is
sufficient to ensure positive operation of radio equipment
without interference, should be provided.
(ix)Braking distance should not be more than 9m at 32 km/hr.
when fully loaded.
1.2 PUMP
(i) The foam tender should be mounted with one centrifugal
type, single /double stage pump.
(ii) The pump should be capable of discharging minimum
4000 lpm at 8.5 Kg/cm2. The suction side of the pump should
be connected to water tank independently.
(iii) The pump should be capable of discharging not less than
150% of the rated capacity at a head not less than 65% of
the rated head. The shut off head of the pump should not
exceed 120% of the rated head for the pumps.
(iv) Pump should be suitably mounted on the rear / midship
on the chassis and should be accessible and readily
removable for repair and maintenance. The pump should
have its control panel installed suitably.
(v) The pump should be of rigid construction and should be
made of gunmetal/ any suitable light alloy, compatible with
firefighting water and foam compound with stainless steel
grade 304 shaft should be suitable for use with saline water.
(vi) The pump impeller shaft should be fitted with antifriction
bearings. (vii) The pump impeller neck rings and impeller
rings should be renewable types and the gland should be
self-adjusting type. A drain plug should be provided at the
bottom of the casing.

36
(viii) Primer: The pump should be fitted with an automatic
water ring /reciprocating primer. It should be capable of
lifting water at least from a depth of 7.0 m at a rate of not
less than 30 cm per second.
(ix) The delivery outlet of the pump should be connected to
the monitor and 4/6/8 numbers of screwed 63 mm female
instantaneous couplings in accordance with IS:903 – 1975.
The monitor and other 63 mm female coupling outlets should
be fitted with lever operated ball valves.
(x) Suction lines should be provided with strainers which
should be removable easily.
1.3 WATER TANK
Water tank of 1800 to 3000 liters capacity should be suitably
mounted on the chassis. It should be fabricated out of Mild
Steel / stainless steel grade 304/316 sheets; of minimum 5
mm thickness for bottom and 4 mm for sides and top. The
gas tungsten arc welding (GTAW) with ER 309 MOL electrode
or equivalent and 100% radiography should be followed. 150
mm / 200 mm water filling pipe on each side of
the vehicle should be provided for water tank filling, fitted
with 2/3 numbers of 63 mm instantaneous male couplings
incorporating a strainer, NRV.
1.4 FOAM TANK
Foam Compound tank of 3000 to 4500 liters capacity should
be mounted on the chassis. It should be fabricated out of
stainless-steel grade 304/316 plates 11 of minimum 5 mm
thickness for bottom and 4 mm thickness for sides & top. All
external surface should be suitably treated to resist
atmospheric corrosion and painted. The foam tank should be
of rigid type rectangular / elliptical in shape with welded
construction. The gas tungsten arc welding (GTAW) with ER

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309 MOL electrode or equivalent 100% radiography is
required. The foam tank should be suitably baffled to prevent
the surges while the vehicle is accelerating, cornering and
braking and should be so designed and mounted as to bring
the centre of gravity as low as possible in the chassis. The
baffles should have flanged man ways of 450 mm dia. The
tank should have minimum 1 no. of 450 mm dia inspection
manhole with hinged or removable covers. The manhole
cover should be marked ‘FOAM’ at the top. The tank should
be provided with a breather valve to enable automatic
venting of the foam compound tank when the foam
compound is drawn from it or when the tank in being filled.

1.5 FOAM COMPOUND PROPORTIONER

Around the pump proportioner with variable setting selector

valve (to induce 3 to 6% of foam compound) should be
provided between the foam compound tank and pump. It
should be designed for operation by water under pump
pressure. Balance foam proportioner with manual override is
optional. The proportioner should be so installed that it
should not be liable to mechanical or other damage. The
selector valve should have four settings beginning with ‘On’
or ‘Off’ position. Each upward setting will result into an equal
increase 12 in the foam compound flow rate. The linkages for
this purpose should be as simple as possible to avoid
distortion due to chassis flexion. It should be very reliable
and should not require frequent calibration checks. Auxiliary
foam pickup tube arrangement from outside should be
provided.
1.6 POWER TAKE OFF UNIT (PTO)

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A power take-off unit of suitable gear ratio to match the
engine & pump characteristics should be provided. A
separate lever in the main cabin should engage the PTO.
Necessary supports for PTO units, propeller shaft couplings,
universal joints etc. for power input to and output from PTO
unit should be provided. The drive assembly components
(shaft, couplings etc.) should be dynamically balanced.
1.7 WATER / FOAM MONITORS
There should be one roof mounted water-cum-foam
aspirating / non aspirating monitor of minimum 2580 lpm
capacity and 60 m horizontal water throw at 7.0 Kg/sq.cm.
The monitor should be capable of traversing through 360o in
a horizontal plane and 90o up and 15o down in the vertical
plane. The monitor and hand-lines should be tested
separately and in combination for delivering foam and water
throw at rated capacity and range; within the pump capacity.

2. FOAM NURSER
The Foam Nurser including all accessories should be designed
and manufactured as per relevant Indian Standards and TAC
requirements wherever applicable and should be as per
sound engineering practice. The specifications given here are
guidelines for material, design, construction and accessories
etc. for Foam Nurser. All the equipment and accessories
should be fixed on the appliance in a compact and neat
manner and should be so placed that each part is easily and
readily accessible for 17 use and maintenance. The centre of
gravity should be kept as low as possible.
2.1 CHASSIS
The foam nurser should be fabricated on a suitable chassis of
pay load capacity 10 tonnes or 16.8 tonnes or 19.0 tonnes.

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The spare wheel assembly (supplied along with chassis)
should be fitted at a suitable place on the appliance. Rest
same as foam tender.
2.2 FOAM TANK
The net capacity of the foam tank should be 7000 to 12000
liters. The tank should have 2% expansion space over and
above foam compound capacity. The materials of
construction of foam tank and fittings should be SS-304 / SS-
316. The foam tank of rectangular / elliptical shape and
should be made of 5 mm. (minimum) for bottom and 4 mm
minimum thick plates for sides and top. The tank should be
welded in construction and should have adequate SS angle
reinforcement. Suitable baffles should be provided inside the
tank, made out of 5mm. SS-304 / SS- 316 plates to prevent
surging, when vehicle is in motion. The baffle plates should
be placed at every 900mm (max.) interval. Hooks should be
provided on roof of the tank for lifting purpose.
2.3 FOAM PUMP
 The pump to handle foam compound should be rotary gear
type. The pump should be driven by chassis engine through
PTO and should meet following specifications:
 Capacity: Minimum 400 lpm at 7 kg. /CM2 (g) discharge
pressure.

o Priming: Self priming under gravity feed from tank and

capable to lift foam from barrel kept on ground.
o Materials: Casing, shaft and other parts coming in contact
with the foam compound should be of SS-304 except gears
manufactured from SS AISI-410.

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o Type of Gears: Double helical, hardened and profile ground.
o Bearings: GM and Teflon bush bearing (replaceable type).
o Shaft Seal: Mechanical seal.

2.5 POWER TAKE-OFF (PTO) UNIT

The Power Take Off (PTO) Unit for driving the pump should be
of suitable type to match the pump characteristics. PTO Unit
should be engaged by a separate lever in the main cabin.
Necessary supports for PTO Units, propeller shafts, coupling,
universal joints etc. for power input to and output from PTO
units should have to be provided. The drive assembly
components (shafts, coupling etc.) should be dynamically
balanced.
3.WATER BOUSER
The specification covers the minimum requirement regarding
design, material, fabrication, workmanship & finish
accessories and acceptance tests of fire water tender of 6000
litre capacity to be used as a major firefighting appliance.
3.1 CHASSIS
The water tank should be fabricated and built on a suitable
chassis of pay load capacity 10 tonnes or 16.8 tonnes.
3.2 PUMP
The Tender should be mounted with one centrifugal type,
single / double stage pump. The pump should be capable of
discharging minimum 4000 lpm at 8.5 Kg/Cm2 . The suction
side of the pump should be connected to water tank
independently. The pump should be capable of discharging
not less than 150% of the rated capacity at a head not less
than 65% of the rated head. The shut off head of the pump

41
should not exceed 120% of the rated head for the pumps.
The pump impeller shaft should be fitted with antifriction
bearings.
Primer: Pump should be fitted with an automatic water ring
/reciprocating primer. It should be capable of lifting water at-
least through 7.0 m at a rate of not less than 30
cm per second. The delivery outlet of the pump should be
connected to the monitor and 4/6/8 numbers of screwed 63
mm female instantaneous couplings should be in accordance
with IS:903 – 1975. The monitor and other 63 mm female
coupling outlets should be fitted with lever operated ball
valves. Suction lines should be provided with strainers which
should be removable easily.
3.3 WATER TANK
Water tank of minimum 6000 liters capacity should be
suitably mounted on the chassis. It should be fabricated out
of MS/Grade 304/316 Stainless Steel sheets; of minimum 5
mm thickness for bottom and 4 mm for sides and top. The
Gas Tungsten Arc Welding (GTAW) with ER 309 MOL
electrode or equivalent and 100% radiography should be
followed. Tank made of MS should be epoxy coated. The tank
should have adequate MS / SS angle reinforcement
3.4 WATER MONITORS
There should be one roof mounted water monitor of minimum
2580 lpm capacity and minimum 60 m horizontal throw at 7.0
Kg/sq.cm. The monitor should be capable of traversing
through 360o in a horizontal plane and 90o up and 15o down
in the vertical plane. The monitor and hand-lines should be
tested separately and in combination for delivering water
throw at rated capacity and range; within the pump capacity.
4. EMERGENCY RESCUE TENDER

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The Emergency Rescue Tender (ERT) including all accessories
should be designed and manufactured as per relevant Indian
Standards and TAC’s requirements wherever applicable and
should be as per sound engineering practice. The
specifications mentioned hereunder lays down the
requirements regarding material, design, construction,
workmanship and finish, accessories and acceptance tests
emergency rescue vehicle. All the equipment and accessories
should be fixed on the appliance in a compact and neat
manner and should be so placed that each part is easily and
readily accessible for use and maintenance. The centre of
gravity should be kept as low as possible. This specification
covers the general requirements regarding materials,
performance and acceptance tests for Emergency Rescue
Tender to be used for Rescue Operations including handling
LPG Emergencies
The scope of supply should be inclusive of, but not limited to
the following:
 Diesel generator set of 5 KVA fitted with CCE approved
spark arrestor & Flood lighting arrangement.
 A battery-operated amplifier system.
 An extension ladders.
 Pneumatic lifting equipment.

 Leak sealing pads

 Leak control kits.
 Low temperature protective suit
 Fire entry suit

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 Fire proximity suit
 Hydraulic spreader and cutter
 Portable gas detectors
 LPG transfer equipment
 Traffic control equipment
 other accessories.

5.MULTIPURPOSE FIRE TENDER

Since the most commonly encountered fire in everyday life is

class A fires, water tenders from the bulk of fire vehicles in
organized Fire Services. However, in the hydrocarbon
industry, B & C classes’ fires are major hazards and so Foam
Tenders are required. The drawback of the two types of fire
tenders above is that they cannot be effectively used in
combating electric fires, for which Dry Chemical Powder
(DCP) is the more appropriate firefighting medium. Initially,
fire tenders in use were catering to each of the above
segment and so water tenders, foam tenders and DCP
tenders were kept in the fire stations. However, the concept
of multipurpose fire tender incorporating all the three
extinguishing medias i.e., water, foam and DCP in the same
vehicle evolved over a period of time and the convenience of
having a single fire vehicle which can be effectively utilized in
fighting all classes of fire gave the ONGC Fire Services more
capabilities in its fire

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ONGC NORMS FOR FIRE FIGHTING
EQUIPMENT AT FIRE STATIONS

45
Recommendation as per OISD 189

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 Conclusion
The thorough study of the processes and the related hazards
was helpful to understand the operations of ONGC and the
ways in which it tackles the hazards to ensure safe operation
at minimal loss of human lives, property and damage to
environment.
Only through earnest effort to follow the safest possible path
under the guidance of the standards laid down by the
industry regulators has ONGC been able to rise to such a
height in both quantity produced and quality of safety and
fire standard.
The study showed that the organization has adopted ‘no-
compromise’ attitude towards the implementation of various
requirements. Yet the company is aware that the ultimate
goal off zero incidents is far to ahead in the future and
requires tireless efforts.

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