PI Foam System Expansion for Storage Tank Fire Safety
A major storage tank company in Hungary is preparing a significant upgrade to its fire-protection systems, aiming to expand an existing automatic extinguishing setup from one tank to three additional tanks and their associated loading and bund areas. The project centres on the PI Foam System, a unique extinguishing technology that has already proved reliable at the site.
For years, the Hungarian division of the German energy-logistics group Oiltanking has depended on the first generation of the PI Foam System to safeguard a gasoline storage tank at its Csepel Island terminal on the Danube River. As part of its broader renovation strategy, the company tasked Swiss Fire Protection R&D, based in Sarnen, with developing a comprehensive plan to extend protection across the entire facility.
What emerged is a study that highlights just how straightforward it can be to scale the PI Foam System from a single-tank solution into a robust, site-wide fire-fighting installation.
A Unique Extinguishing System
The PI Foam System stands out in the industrial fire-protection sector because it does not rely on pumps for foam generation. Instead, the system uses a pressurised vessel that creates foam instantly when triggered. This vessel connects to designated areas around a facility through temperature-resistant piping.
When a fire is detected, sensors send a signal that opens the relevant valves. A powerful surge of foam is then released, flooding the fire area within seconds. This rapid response reduces structural damage and enhances firefighter safety. And because the system is not restricted by pump capacity, it can be scaled to protect industrial sites of virtually any size.
Designing Expansion for a Complex Facility
Oiltanking’s request called for a system upgrade capable of providing uninterrupted foam supply to all four fuel-storage tanks, including their bunds, the pump stations, and loading facilities for trucks, trains, and barges.
The tank farm consists of:
- One 5,000 m³ gasoline tank with a ring wall and fixed roof
- Two 5,000 m³ diesel tanks
- One 2,000 m³ diesel tank
- Associated bund areas and loading infrastructure
The design also required the system to manage a worst-case scenario: simultaneous fires at the facility’s largest tank and its bund. This combined fire surface area totals 1,878 m², roughly equivalent to a single storage tank with a 43.5-metre diameter.
To meet these demands, SFPRD engineers divided the terminal into four extinguishment zones, the largest measuring 5,270 m² and covering all four tanks. Each zone is connected to two pressurised foam vessels with 38 m³ capacity, supplied through independent branch pipe networks. These vessels are installed in controlled environments to prevent exposure to freezing or excessive heat.
Pipe diameters vary according to the surface area each zone protects. During an incident, only the valve for the affected zone opens, directing foam precisely where needed and keeping other sections dry. This targeted activation ensures efficient foam use and system reliability.
How the System Handles Real Fires
Foam is delivered directly onto the fire surface through specialised dispensers. Once a fire is extinguished, residual fuel and foam drain into a dedicated containment pit that feeds into an isolated drainage system to prevent contamination. Foam left inside the vessel and pipes remains fully reusable.
The system also integrates seamlessly with supplementary equipment such as foam monitors and hoses, allowing response teams to tackle both large-scale and localised fires. Because it uses few moving parts, the likelihood of mechanical failure is extremely low, and ongoing operating costs are substantially lower than maintaining on-site firefighting teams around the clock.
Future Applications
Swiss Fire Protection R&D is now developing versions of the PI Foam System for high-rise buildings and ocean-going freight vessels. Its adaptability allows it to deliver complete protection for nearly any type of facility, from petrochemical plants to logistics hubs.
Final approval for the expanded system at Oiltanking Hungary is expected soon, marking another milestone in the evolution of scalable, pump-free industrial fire protection.
