Introduction
The Yanpet EG2 Efficiency Improvement Project focuses on improving the operational efficiency, process safety, and reliability of the existing Ethylene Glycol (EG) Unit at the Yanbu Petrochemical Company complex in Yanbu. The project includes modifications and upgrades to existing process facilities to enhance production performance, improve energy efficiency, and maintain safe plant operation.
As part of the project, a comprehensive 3D Fire and Gas (F&G) Mapping Study was conducted to evaluate flame and gas detector coverage, optimize detector placement, and strengthen the overall fire and gas detection strategy in accordance with international industry standards and operational requirements.
iFluids Engineering Abu Dhabi successfully performed the Fire & Gas Detection Mapping Study for the project on behalf of Sinopec Nanjing Engineering, ensuring improved detector coverage and enhanced plant safety performance.
Objective of the Fire & Gas Mapping Study
The objective of the 3D Fire & Gas (F&G) Mapping Study was to design and evaluate an effective fire and gas detection system capable of identifying hazardous gas releases and fire scenarios at an early stage. Early detection helps operators respond quickly and prevents escalation into major industrial incidents.
The study adopted a performance-based Fire & Gas assessment methodology that linked detector effectiveness with credible hazard scenarios. The assessment also considered integration with emergency shutdown systems and fire protection systems to ensure reliable automatic and manual response capabilities.
Recognized for excellence.
PROJECTS DELIVERED ACROSS THE GLOBE
Key Objectives
- Improve personnel safety within the Ethylene Glycol Unit
- Enhance emergency escape and evacuation capability
- Reduce the risk of fire and gas incident escalation
- Optimize flame detector and gas detector placement
- Improve long-term detector maintenance efficiency
- Strengthen the plant’s overall process safety framework
3D Fire & Gas Mapping Methodology
The Fire & Gas Mapping Study was carried out using advanced 3D modelling and detector coverage assessment techniques to evaluate the effectiveness of existing and proposed detector locations across the Ethylene Glycol Unit.
The assessment included:
- Identification of hazardous release scenarios
- Review of plant layouts and congestion areas
- 3D flame detector coverage analysis
- Combustible gas detector coverage assessment
- Detector visibility and obstruction analysis
- Optimization of detector positioning
- Evaluation of detector redundancy and performance targets
- Preparation of detector coverage plots and 2D layouts
Detector coverage performance was evaluated based on zone-wise risk assessment and project-specific Fire & Gas Mapping criteria.
Codes and Standards
The Fire & Gas Detection Mapping Study was performed in accordance with internationally recognized standards and engineering guidelines.
| Codes and Standards | Description |
|---|---|
| ISA-TR84.00.07-2018 | Guidance on evaluation of Fire, Combustible Gas, and Toxic Gas System effectiveness |
| SAES-J-505 | Combustible Gas and Hydrogen Sulfide Detection Systems |
| SABP-B-104 | Guidelines for Performing Fire & Gas Mapping Studies |
| NFPA 72 | National Fire Alarm and Signaling Code |
Fire & Gas Mapping Results and Discussion
The Fire & Gas Detection Study was performed using specialized Fire & Gas Mapping software to assess existing detector coverage and identify opportunities for optimization.
Based on the zone-wise assessment results:
- Existing detector layouts were reviewed and optimized
- Strategic detector relocation and removal were carried out within specific zones
- Additional flame detectors were introduced to improve fire detection coverage
- Point-type gas detectors were added to strengthen combustible gas detection performance
- Detector coverage targets and performance requirements were successfully achieved
Detector Coverage Snapshot
The final study deliverables included:
- Detector coverage snapshots
- Optimized detector coordinates
- 2D detector layout drawings
- Coverage performance assessment reports
- Fire & Gas detector optimization recommendations
The study significantly enhanced Fire & Gas detection reliability and improved overall safety coverage for the Ethylene Glycol Unit at the Yanpet Petrochemical Complex in Saudi Arabia.
Why 3D Fire & Gas Mapping is Important for Petrochemical Plants
3D Fire & Gas Mapping Studies help petrochemical facilities improve detection reliability by identifying blind spots, optimizing detector locations, and validating detector performance against realistic hazard scenarios.
Benefits include:
- Improved fire and gas hazard detection
- Faster emergency response capability
- Reduced incident escalation potential
- Better compliance with international safety standards
- Improved operational safety and reliability
- Enhanced plant risk management performance
Need a Fire & Gas Mapping Study for your facility?
Contact iFluids Engineering Abu Dhabi for Fire & Gas Mapping Studies, Flame Detection Mapping, Gas Detector Coverage Assessment, HAZOP, SIL, and Process Safety Engineering services across the Middle East. Connect with our experts today.
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