OISD 116 2017 vs 2025 | Comparison of Updated Fire Protection Standard for Refineries & Petrochemical Plants

Fire safety in the oil & gas sector has never been more critical. With refineries, gas processing plants, and petrochemical facilities handling highly flammable hydrocarbons round the clock, the need for a robust fire protection standard is essential, not optional.

In India, OISD 116 is the backbone of fire protection design for these high-hazard facilities. The 2017 edition served as the core compliance standard for almost eight years. However, the OISD 116 (2025) revision introduces major updates to fire safety, reflecting new technologies, new hazards, and global best practices.

If you’re a safety engineer, design consultant, EPC contractor, operations head, or compliance auditor this guide gives you everything you need.

Why the OISD 116 Revision Matters in 2025

Refineries and petrochemical complexes have evolved drastically since 2017:

• More integrated petrochemical units
  
• Higher LPG, hydrogen, and lighter ends handling
  
• Increased cryogenic applications like LNG
  
• Growth of polymer and mega complex units
  
• Explosion and fire incidents in India that triggered regulatory upgrades

The updated OISD 116 (2025) responds to these realities and aligns with international references like NFPA 13, NFPA 15, NFPA 17, and IS 15105, strengthening India’s fire protection ecosystem.

Understanding the Scope of OISD 116

Before we compare OISD 116 2017 vs 2025, it’s important to know the purpose of this standard.

OISD 116 is India’s fire protection standard for:

• Petroleum refineries
  
• Gas processing plants
  
• Petrochemical complexes (added explicitly in 2025)
  
• Onsite tank farms
  
• Offsite facilities inside refinery boundaries

It covers:

• Fire water system
  
• Foam systems
  
• HVLR monitors
  
• Water spray systems
  
• Detection and alarm systems
  
• Emergency response
  
• Active & passive fire protection
  
• Fire station and firefighting equipment
  
• Inspection, testing & maintenance

OISD 116 2017 vs 2025 | Summary of Key Differences

If you want the short answer, here is the quick snapshot of the major changes.

What’s New in OISD 116 (2025)

• Explicit inclusion of petrochemical complexes
  
• More prescriptive requirements for tank farms
  
• Higher design clarity for High Volume Long Range monitors
  
• More emphasis on hydrogen, LPG, lighter ends
  
• New water spray rules for tall columns (≥ 45 m)
  
• Mandatory sprinklers for polymer/petrochemical areas
  
• New water curtain systems for cracker furnaces
  
• New fire protection rules for cryogenics
  
• flammable liquid handling areas
  
• Stronger rules for coal handling & conveyors
  
• Updated definitions and terminology
  
• Modernized standby pump philosophy
  
• Updated requirements for pressure, flow, network integrity

When you see the side-by-side table later, you will realize the 2025 edition is not a cosmetic update, it is a complete upgrade.

Detailed Comparison of OISD 116 2017 vs 2025

Let’s now break down the comparison clause-by-clause, as would a senior safety engineer.

1. Scope Revision 

Old (2017)

Covers refineries & oil/gas processing plants.

New (2025)

Explicitly includes petrochemical complexes within the refinery boundary.

What this means

• Polymer, cracker units, polymer bagging, pelletising, gasoline hydrotreaters, etc. now fall directly under OISD 116 compliance.
  
• Removes ambiguity that previously required cross-referencing OISD 144, OISD 169, OISD 218 etc.

Result → wider applicability and higher enforcement across integrated complexes.

2. Updated Definitions 

Added in 2025:

• Auto-ignition temperature
  
• Tank
  
• Water spray system
  
• Water sprinkler system
  
• Control room
  
• Petrochemical complex

Revised:

• Classification of fire
  
• Oil & gas processing plants

Why this matters:
These definitions are the backbone for determining whether a specific equipment requires:

• Water spray
  
• Sprinkler
  
• Foam
  
• Monitor protection
  
• Clean-agent flooding

Better clarity = fewer disputes in audits.

3. Fire Protection Philosophy | Major Revisions

3.1 Tank Farm Fire Protection

2017

Water spray and foam systems allowed some flexibility.

2025 (Huge change)

• Water spray mandatory for all Class A petroleum tanks with:
  
  • Capacity > 190 m³ or
    
  • Diameter > 6 m
    
• Semi-fixed foam system required for fixed-roof tanks ≥ 9 m diameter.
  
• Minimum foam chamber outlets clearly defined (2 to 8 based on diameter).

Impact:
Tank farms will need significant upgrades especially older depots and refineries.

3.2 LPG / Lighter Ends / Hydrogen Protection

2017

General guidelines existed, but not very prescriptive.

2025

• Automatic water spray required for:
  
  • LPG/C4 vessels
    
  • Hydrogen compressors
    
  • Loading/unloading gantries
    
  • Pumps handling hydrocarbons above auto-ignition temperature

This shift to automatic systems drastically reduces response time in fire scenarios.

3.3 Process Units | Water Spray Protection

2025 additions:

• Uninsulated vessels > 50 m³ storing Class A/B require water spray.
  
• Columns > 45 m require:
  
  • Water spray rings OR
    
  • 2 remote monitors OR
    
  • High-capacity trolley monitors
    
• Automatic spray required for LPG pumps & hydrogen facilities.

This is one of the most important changes in the OISD 116 revision.

3.4 Sprinklers for Petrochemical Structures

OISD 116 (2025) specifies:

• Polymer extruder buildings
  
• Bagging areas
  
• Pelletising buildings
  
• Warehouse storage
  
• Basement car parking

Uses NFPA 13 / IS 15105 for design.

3.5 Water Curtain Systems

New in 2025

Required in:

• Naphtha cracker furnaces
  
• Gas cracker units
  
• Hydrocarbon gas handling areas near furnaces

Activated via hydrocarbon detectors.

This reflects global practices in ethylene/petrochemical complexes.

3.6 Clean Agent Systems

2025

• Control room
  
• Instrument panel rooms
  
• Satellite rack rooms

All clean-agent systems must be approved/listed by:

• UL –  Underwriters Laboratories (USA)
  
• FM – Factory Mutual Approvals (USA)
  
• VdS – VdS Schadenverhütung (Germany)
  
• LPCB – Loss Prevention Certification Board (UK)
  
• BIS – Bureau of Indian Standards (India)

Why OISD 116 (2025) Mandates These Certifications

Because clean-agent systems protect critical spaces like:

• Control rooms
  
• Instrument panel rooms
  
• Satellite rack rooms (SRR)
  any failure can lead to complete plant shutdown or catastrophic loss.

The certifications guarantee that:

• the extinguishing system activates correctly
  
• the agent concentration is sufficient
  
• cylinders withstand pressure variations
  
• discharge patterns match design
  
• electronics and detection panels work reliably

In short, these approvals ensure global-quality, fail-safe fire suppression.

3.7 Coal & Conveyor Protection

2025 introduced section

Refineries / petchem with captive power using coal must follow:

• HVWS for boiler fronts
  
• MVWS with wetting agent for coal silos
  
• Sprinklers for conveyors
  
• Fire detection at transfer points

3.8 Cryogenic Liquids

New in 2025

For LNG, LOX, LH₂ and other cryogenics:

• High-expansion foam for DWS tanks
  
• Suitable extinguishers
  
• Dedicated PPE
  
• Hydrant/monitor coverage as per standard

4. Fire Water System Guidelines | Biggest Overhaul 

OISD fire water system guidelines.

4.1 Fire Water Demand

2017

General flow requirements.

2025

More refined:

• For tank farms → 3 lpm/m² on shell area for all unaffected tanks
  
• Simultaneous fire scenarios refined

4.2 Fire Header Pressure

• 7 kg/cm² at remotest point
  
• 5.25 kg/cm² at elevated landing valves

These values are now explicitly stated, reducing interpretation errors.

4.3 Fire Water Pumps | Big Philosophy Change

2017

Simpler standby logic.

2025

• ≤ 2 working pumps → 1 standby
  
• 3–4 working → 2 standby
  
• 4 working → 3 standby
  
• Jockey pumps = 1% of system demand

4.4 Power Supply

A fire pump switchboard must have two inverters to ensure redundancy.

4.5 Fire Water Network Integrity

• Underground ring main must have corrosion-resistant coating
  
• Coating must extend 300 mm above grade

5. High Volume Long Range Monitors | Major Redesign

This section directly aligns with:
“OISD norms for tank farm fire safety”
“OISD foam system requirements”

2025 Enhancements:

• Application rate: 9.75 lpm/m², considering 50% wind losses
  
• Minimum two monitors per tank
  
• Upwind positioning
  
• Must reach centre of tank surface
  
• Must be UL/FM/BIS certified

This is significantly more prescriptive than the 2017 version.

6. Foam System Requirements 

New in 2025

• Detailed table with number of foam outlets vs tank diameter
  
• Vapour seal chamber fragile seal at 10–25 psi
  
• Updated foam concentrate requirements
  
• Clear criteria for:
  
  • Mobile foam units
    
  • Trailer-mounted foam monitors
    
  • Foam bladder tank systems

OISD 116 (2025) introduces much more detailed foam system design criteria.

7. Fire Detection & Alarm Enhancements

2025 additions:

• Toxic gas detection
  
• HC detector-activated water curtains
  
• New logic for automatic activation
  
• More clarity on alarm zoning

8. Fire Station, Response & Mobile Equipment

2025 emphasises:

• Modern fire tenders
  
• High-flow trailer monitors
  
• Enhanced training ground requirements
  
• Battery fire considerations (reflects trend of BESS in refineries)

9. Inspection, Testing & Maintenance (IT&M)

2025 emphasises:

• Record-keeping
  
• Fire pump health monitoring
  
• Spray/sprinkler periodic testing
  
• Foam concentrate testing
  
• Fire drill observations

Side-by-Side Comparison Table: OISD 116 2017 vs 2025

Topic	OISD 116 (2017)	OISD 116 (2025)
Scope	Refineries + gas processing	Adds petrochemical complexes
Tank Farm Protection	General guidelines	Mandatory spray, fixed outlets, foam chamber count
LPG/H₂ Facilities	Limited	Automatic water spray
Columns > 45m	Not clear	Mandatory protection options
Petrochemical Units	Not specified	Mandatory sprinklers
Water Curtain	Not included	Required for crackers
Cryogenics	Not covered	Detailed requirements
Coal Handling	Not covered	Detailed requirements
Fire Water Design	Moderate detail	Highly prescriptive
HVLR Monitors	Less defined	Detailed coverage + certification
Foam Systems	General	Tables, fragile seal, UL/FM
Detection	Basic	Toxic gas + HC detector integration
IT&M	Standard	More structured, more frequent

Who Must Upgrade Based on OISD 116 (2025)?

• Refineries older than 15–20 years
  
• Petrochemical complexes integrated with refineries
  
• Tank farms with large Class A/B tanks
  
• Hydrogen facilities
  
• LPG/C4 handling units
  
• Crackers & polymer plants
  
• LNG or cryogenic installations
  
• Coal-based captive power systems

Conclusion: OISD 116 2025 is a Complete Modernization, Not Just a Revision

The comparison of OISD 116 2017 vs 2025 shows that India’s fire protection standard has undergone a massive transformation. The 2025 edition:

• Closes long-standing gaps in petrochemical fire protection
  
• Introduces global-standard requirements
  
• Mandates automatic protection for high-hazard units
  
• Modernizes tank farm and foam system design
  
• Strengthens fire water system reliability
  
• Improves coverage for cryogenics, hydrogen, LPG, coal systems

In short, OISD 116 (2025) is designed to ensure that India’s refinery and petrochemical infrastructure can withstand modern fire and explosion hazards with best-in-class engineering.

Facilities should start gap assessment, fire water hydraulic studies, foam system redesign, High Volume Long Range coverage analysis, and layout compliance checks immediately to meet the updated requirements.