F&G 3D Mapping Study (Gas Detection Review Study) For MRPL Devanagonthi Project 

Marketing terminal at Devangonthi by Mangalore Refinery and Petrochemicals Limited. This terminal consists of tanks holding different products such as MS, HSD, ATF, Ethanol and Biodiesel. Marketing terminal receives products through Pipelines from PMHBL & Tank truck and dispatch the products to Tanker truck stationed in Bays. 

Mangalore Refinery and Petrochemicals Limited has planned to review Hydrocarbon Vapor detection for Class A Product Tank farm and handling areas in Marketing terminal at Devangonthi, Bangalore. This terminal consists of Tank farms, pumps and its associated pipelines.

Yokogawa India Limited awarded iFluids Engineering to carry out Fire and Gas Mapping Study for Marketing terminal project of Mangalore Refinery and Petrochemicals Limited at Devangonthi, Bangalore. This document describes the methodology and study results of Fire and Gas Mapping Study conducted at Marketing terminal of Mangalore Refinery and Petrochemicals Limited at Devangonthi, Bangalore.


Marketing Terminal has the following facilities,

  • MS Tank (3 No’s)
  • Ethanol Tank (2 No’s)
  • HSD Tank (3 No’s)
  • ATF Tank (3 No’s)
  • Biodiesel Tank (2 No’s)
  • MS underground Tank
  • Slope Tank
  • Pump House
  • Gantry Area

In addition to the above mentioned equipments,  Bulk Air Eliminator of (MS, Ethanol, ATF), Vapor Recovery Unit, Fire water system, Instrument Air system, Chemical dosing systems were available at the Terminal.

The scope of work includes the following activities for Fire and Gas Mapping study of Marketing terminal.

The Fire and Gas Mapping Study covers Class A Petroleum Liquid handling facilities in the Marketing terminal that have flash Points below 23°C.

The F&G Study suggests the location, type and number of detectors that needs to be installed across various areas.

The objectives of F & G Mapping study for Marketing terminal are:

  • Identifying all potential hazards that leads to release or ignition of flammable gas
  • Proposing new fire and gas detection arrangements.

Although a plant free of gas releases and fires is the goal in design and management of refineries, storage and handling facilities, the risk of a release or fire is never zero. Few areas of plant have  greater risk than others. The item confined, the environment in which it is contained, and the containment tools and procedures used all have an impact on the risk.

Early detection and subsequent mitigating measures can lower the risk of flammable or poisonous gas discharges or fires. The process operators frequently provide effective detection and response to a release or fire in the course of their regular duties. However, occasionally the event’s nature necessitates a quicker notice and response than the operator is capable of providing. Additionally, the increased use of remote monitoring and automation can reduce the time an Operators spends on an unit, possibly increasing the time to detect a leak. An instrumented monitoring system can be employed when more rapid detection is required than the process operator can deliver.

Installations are equipped with fire and gas detection systems so that the possibility of inadvertent poisonous and flammable gas releases or ignition sources, which could endanger the installation or its occupants, can be identified in advance.

By lessening the severity of the release, toxic gas, flammable gas, and fire detectors can lower the risk of a release. Severity is reduced as a result of  faster response. The response may be carried out through the operator or through an automated response. Automated reactions include systems for stopping and/or isolating machinery as well as automated systems for foam, water spray, or deluge.

To assist in deciding how many gas and flame detectors to install, the F & G research was conducted.

The below mentioned steps give a brief description of the approach followed in Fire and Gas Mapping Study.

The Methodology to undertake F&G Mapping study includes the following steps:

  • Demonstrate adequate F&G detection coverage for facilities under project scope.
  • Prepare an optimized F&G layout.
  • Prepare a F&G Mapping report which includes detector co-ordinates, detector coverage, alarm settings and voting logic.

For the purpose of detecting 3D modeling, a hybrid strategy was used, in which detectors were positioned on both scenario-based and geographic approaches.  The benefit of this strategy is that it will require far fewer detectors while producing superior coverage outcomes. Scenario based approach is to place detectors at all LOC scenarios and Geographic Approach is to geographically place detectors to cover the nearby surrounding area. The number of detectors in this study was minimized based on geographic location, meaning that for close equipment, common detectors were installed without compromising the performance coverage objective of the desired equipments. In this study, the detectors were positioned near LOC situations of the equipment.