DOC. NO.

REV. NO. 0

Agnice Fire Protection Pvt. Ltd

PLL AGNICE

PLL-GVK-PEM-127-W-001

O&M MANUAL FOR FIRE PROTECTION SYSTEM

0 REV. NO.
PROJECT OWNER

FOR APPROVAL DESCRIPTION

NFA
PRED. BY

NFA
CHKD. BY

MJ
APPD BY

22/01/2013 DATE

2x270 MW, COAL BASED TPP GOINDWAL SAHIB PUNJAB GVK POWER (GOINDWAL SAHIB) LIMITED

OWNER'S CONSULTANT

TCE CONSULTING ENGINEERS LIMITED,

BANGALORE

BOP CONTRACTOR

PUNJ LLOYD LIMITED,

95 INSTITUTIONAL AREA, SECTOR 32. GURGAON 122-001.

BOP CONSULTANT

FICHTNER Consulting Engineers (India) Private Limited Chennai

OPERATION AND MAINTENANCE MANUAL

CONTENTS
1. INTRODUCTION 2. PREFACE 3. REFERENCE DRAWINGS 4. SYSTEM DESCRIPTION 5. SYSTEM OPERATION 6. COMMISSIONING PROCEDURE 7. ROUTINE TESTING 8. MAINTENANCE CHART 9. DRAWINGS AND DATASHEETS

OPERATION AND MAINTENANCE MANUAL

1. INTRODUCTION

OPERATION AND MAINTENANCE MANUAL

1. INTRODUCTION
Fire is an external sign of chemical action, usually the combination of Carbon and Hydrogen with Oxygen, resulting in the release of heat energy. Fire is a necessary evil. When fire is under humans control, it is a great asset. If human is under fires control, fire is a devastating foe.

If fire occurs, how best can it be dealt with to extinguish.

Firstly, by adopting the right mental attitude. With knowledge and ability, a fire fighter can attack a fire in the right manner and, by knowing its weakness, extinguish it in a short time. Without knowledge and ability, the fire will find out their weakness. For fire is a foe, against which no liberties can be taken. Fire should not be thought of as an intimate object. Fire, which starts unseen as a small flicker of flame, may grow at such a pace that it can quickly get out of hand. Once found, it must be extinguished with all the speed and means available or it will destroy those who seek to restrain it. Fire, when apparently extinguished, some untrained person may assume that because the flames have gone, the danger is passed, but it may not be so.

Secondly, by considering each fire as an individual occurrence, the correct action in each case will depend on the position of the fire, the combustibles involved and the combustibles, which are in danger of becoming involved. There is no hard and fast rule; one who has the knowledge and training can only assert the correct action.

OPERATION AND MAINTENANCE MANUAL Thirdly, by ensuring that properly maintained appliances are available for personnel to use and that all fire fighting, fire detection and alarm systems are in fully operational order.

With the rapid growth of the industries and expansion of cities, fire hazards have also increased. Through considerable attention is being paid by the authorities concerned towards fire prevention and fire protection, a possible outbreak of fire cannot be detected and forestalled without an Automatic Fire Alarm System. In the absence of such a system, it is also not possible to ensure (a) an immediate transmission of call on the fire brigade in the event of an out break of fire in any premises during the closed hours, and (b) an effective control of a fire in the incipient stage, with the help of first aid and fire appliances.

An Automatic Fire Alarm and Extinguishing System function through different type of detectors distributed in the premises to be protected, which causes the alarm to be actuated automatically, whenever there is possibility of a fire breaking out or immediately upon the outbreak of fire. The system helps evacuation of the premises, and extinguishes the fire as quickly as possible.

OPERATION AND MAINTENANCE MANUAL

2. PREFACE

OPERATION AND MAINTENANCE MANUAL

2. PREFACE
The purpose of this Manual is to appraise the user on the operation and maintenance of Fire Protection System designed, installed and commissioned by AGNICE FIRE PROTECTION LTD., Chennai for Fire detection & alarm and fire Protection system at 2X270 MW Coal Based TPP,Goindwal Sahib Punjab.

The Fire Protection & Detection System consists of Fire Hydrant System, High Velocity Water Spray System, Medium Velocity Water Spray System, Foam system, Fire Detection and alarm system and Portable Fire Extinguishers. All the systems are designed and installed as per the specification and also as per rules and regulations of Tariff Advisory Committee and National Fire Protection Association. Needless to say, that the efficiency and effectiveness of the system largely depends upon proper maintenance of the system and regular training of the personnel operating the system. Therefore, the system shall be operated and maintained by trained personnel as per guidelines given in this manual.

OPERATION AND MAINTENANCE MANUAL

3. REFERENCE DRAWINGS

OPERATION AND MAINTENANCE MANUAL

3. REFERENCE DRAWINGS
3.1 Pump house, Hydrant, Spray & FDA System & Foam system

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P & l Diagram of Fire Hydrant & Spray System Deluge valve arrangement for MVWS and HVWS System P & l Diagram of Pump house P&I Diagram of Foam System Schematic for Fire alarm and Detection System Composite Layout & Isometric of fire Hydrant and Spray System Layout & Isometric of Fire Water Pump House Fire Escape Hydrant Layout & Isometric for Boilers. Fire Escape Hydrant Layout & Isometric for Control Building. Fire Escape Hydrant Layout & Isometric for ESP Control Building. Fire Escape Hydrant Layout & Isometric for Admin. Building. Fire Escape Hydrant Layout & Isometric for transfer Towers Layout & Isometric of HVW Spray System for Boiler Burner Fronts

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Layout & Isometric of HVW Spray System for Clean and Dirty Oil Tank. Layout & Isometric of HVW Spray System for Generator Seal Oil Tank Cooler and pumping unit Layout & Isometric HVW Spray System for Generator transformer. Layout & Isometric of HVW Spray System for Station Transformer. Layout & Isometric of HVW Spray System for Unit Auxiliary Transformer. Layout & Isometric of HVW Spray System for Main Lube Oil Tank. Layout & Isometric of HVW Spray System for Boiler Feed Pump and Lube Oil cooler. Layout & Isometric of HVW Spray System for Turbine Oil Canal. Layout & Isometric of Foam System for HFO and LDO Tanks. Layout & Isometric of MVW Spray System for Coal conveyor BCN-1 Layout & Isometric of MVW Spray System for Coal conveyor BCN-2 Layout & Isometric of MVW Spray System for Coal conveyor BCN-3 Layout & Isometric of MVW Spray System for Coal conveyor BCN-4A/B Layout & Isometric of MVW spray System for Cable Galleries In T.G Building. Layout & Isometric of MVW Spray System for Coal conveyor BCN-5 Layout & Isometric of MVW Spray System for Coal conveyor BCN-7 Layout & Isometric of MVW Spray System for Coal conveyor BCN-8A/B Layout & Isometric of MVW Spray System for Coal conveyor BCN-9A/B Layout & Isometric of MVW Spray System for Coal conveyor BCN-10A/B

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Layout & Isometric of MVW Spray System for TH-1 transfer tower Layout & Isometric of MVW Spray System for TH-2 transfer tower Layout & Isometric of MVW Spray System for TH-3 transfer tower Layout & Isometric of MVW Spray System for JNT-1 transfer tower Layout & Isometric of MVW Spray System for JNT-2 transfer tower Layout & Isometric of MVW Spray System for JNT-3 transfer tower Layout & Isometric of MVW Spray System for JNT-3 transfer tower Layout of Fire alarm and detection system for TG Building. Layout of Fire alarm and detection system for ESP control Building. Layout of Fire alarm and detection system for Switch Yard control Room. Layout of Fire alarm and detection system for CHP Control room Layout of Fire alarm and detection system for Coal Conveyors 1-4 Layout of Fire alarm and detection system for Workshop and ware house. Layout of Fire alarm and detection system for Air Compressor house. Layout of Fire alarm and detection system for Fuel oil pump house. Layout of Fire alarm and detection system for service building.

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Layout of Fire alarm and detection system for Canteen. Layout of Fire alarm and detection system for Water Treatment Plant. Layout of Fire alarm and detection system for Admin building. Layout of fire detection and alarm system for fire water pump house Layout of fire detection and alarm system for fire station building Layout of Fire alarm and detection system for Coal Conveyors 5-10 Layout of Fire alarm and detection system for LDO & HFO storage tanks Layout of fire detection and alarm system for store building Layout of Fire alarm and detection system for cooling water pump house Layout of Fire alarm and detection system for Ash water cum ash slurry pump Layout of Fire alarm and detection system for Raw water pump house Out Door cabling area

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OPERATION AND MAINTENANCE MANUAL

4. SYSTEM DESCRIPTION

OPERATION AND MAINTENANCE MANUAL

4. SYSTEM DESCRIPTION & DESIGN BASIS

4.1 Scope The following systems are provided for the plant: 4.1.1 4.1.2 4.1.3 Fire water Pumping system. Hydrant System. Automatic Spray system. A. High velocity water spray system. (HVWS) B. Medium velocity water spray system. (MVWS) 4.1.4 Manual Spray System A. Medium velocity water spray system. (MVWS) 4.1.5 4.1.6 4.1.7 Mechanical Fixed foam system for HFO & LDO tank. Portable Fire Extinguishers. Fire Detection and Alarm System.

4.2 Codes and Standards Proposed Fire Fighting System will be inline with TAC Norms/NFPA Standards /IS codes. In general the following codes are followed to design the systems. 1. Hydrant System - Fire protection Manual by TAC 2. Spray system - Rules for water spray systems by TAC 3. Foam system - NFPA11 (Standard for Low, Medium & High expansion Foam) 4. Fire extinguishers - Fire protection Manual by TAC 5. FDA system - IS 2189,TAC (Selection, installation and maintenance of automatic fire detection and alarm system).

OPERATION AND MAINTENANCE MANUAL 4.1.1 Fire Water pumping System The entire Pumping system including main & standby fire pumps, Jockey pumps, their drive motors and diesel engines complete with fuel systems, piping, fittings and valves are designed as per TAC regulations.

All fire pumps (both for Hydrant service and spray water service) are of identical design based on spares interchangeability criteria.

The fire pumps shall be provided with an adjustable starting time delay of 0 to 20 seconds to avoid starting all the pumps simultaneously due to sensing the same low pressure. The fire pumps starting sequence are automatic based on preset system pressure levels conforming to TAC.

The fire pumps and jockey pumps are vertical turbine discharge type.

OPERATION AND MAINTENANCE MANUAL 4.1.2 Hydrant System This Plant is classified under Ordinary Hazard occupancy as per Fire Protection Manual of TAC. The Fire Hydrant System for this plant is designed as per the rules applicable to Ordinary Hazard Occupancy. The Fire Hydrant System is a wet system and it will be under pressure at all times. The System consists of under ground and above ground pipes with hydrant outlets. Under ground and above ground mains are laid as per approved drawings. Pipes are of M.S.ERW pipes and have been coated and wrapped with anti corrosive tape & above ground pipes are painted with paints to prevent corrosion of pipes. For easy maintenance of underground mains, Isolation Valves have been provided at strategic locations to ensure that the section under maintenance is isolated from the other areas in such a way that rest of the hydrant system is always available for fire fighting service.

Near each yard hydrant point, a hose box has been located to provide 2 Nos. of hoses and 1 no. of branch pipe. In the event of fire, the hydrant near to the vicinity of the fire will be opened and the water will be directed to the bottom of fire. Since the pressure in the hydrant mains drops rapidly the same will be sensed by pressure switch. As a result, the pumps will start automatically to cater the requirement.

OPERATION AND MAINTENANCE MANUAL 4.1.3 Spray System The term Water Spray refers to the use of water in a form having a predetermined pattern, particle size, velocity and density discharged from specifically designed nozzles or devices. Water Spray Systems are usually applied to special fire protection problems since the protection can be specifically designed to provide for effective fire control, extinguishment, and prevention or exposure fire protection. These systems may be independent of or supplementary to, other forms of protection. These rules are intended to cover water spray protection from fixed nozzles only. The design of specific systems may vary considerably depending on the nature of the hazard and basic purpose of protection. Because of these variations and other environmental factors, the systems must be competently designed, installed and maintained. Water spray systems are most commonly used to protect processing blocks, processing equipments, structures, flammable liquid and gas vessel, piping and equipment such as transformers, oil switches and some combustible solids, cable trays, cable rack, etc. A special fixed pipe system connected to a reliable source of fire protection water supply and equipped with water spray nozzles for specific water discharge and distribution over the surface or area to be protected. The piping system is connected to the water supply through an automatically actuated Deluge valve which initiates flow of water. Automatic actuation is achieved by operation of automatic detecting equipment installed along with water spray nozzles.

OPERATION AND MAINTENANCE MANUAL A. Automatic HVWS System Automatic H.V.W.S System is provided for Transformers, Lube oil tanks & cooler, Boiler feed water pumps cooler, Boiler Burner front. Detection system shall be of quartzoid bulbs and both detection and protection lines shall be supervised using pressure switch. Deluge valve can be opened either hydraulically by the pilot head detectors or manually. The system shall be actuated in any one of the following ways during a fire condition. 1. In case of fire, the Quartzoid bulb shall break thereby releasing the pressure in the detector network. This shall hydraulically open the deluge valve thus allowing water to be sprayed on the transformer through projectors in the form of a solid conical emulsifying spray. 2. Emergency manual release station is also provided in addition to the above. B. Automatic MVWS System Automatic M.V.W.S System is provided for Cable galleries, Conveyors, Transfer Points and Fuel Oil Unloading Pump House& pressurizing unit. The system consists of smoke detectors and LHS cables for fire detection. The fire protection line is supervised using a pressure switch. The deluge valve can be - opened electrically using solenoid automatically. Manual actuation by releasing the emergency release station is also provided. Coal Conveyor Galleries / Conveyor Tunnels: 1. Coal conveyor spray system is designed with a density of 10.2lpm/Sq.M. 2. Spray system for each zone shall consist of spray nozzles mounted on a water pipe network. Spray system shall cover both forward and return belts. 3. On detection of fire, the spray systems over the affected zone, and the zones immediately preceding and succeeding zones will activate automatically. 4. The fire detection system for all coal conveyors comprises of infrared ember detectors, one located near the head end and one located near the mid way between the head and tail and third near tail end of each conveyor.

OPERATION AND MAINTENANCE MANUAL 5. The infrared ember detectors are solar blind and provided with fluorescent light filters. The detectors have 900 half power cone of vision and housed in a corrosion resistant enclosure. 6. Detectors have facility for lens cleaning using compressed air for which 6 mm size purge air connector is provided for each detector. 7. Three runs of LHS cables are provided running all along the conveyor to cover top, bottom belt and rollers etc. Cable galleries/ Cable vaults in TG Area: 1. Cable gallery spray system is designed with a density of 12.2lpm/Sq.m 2. Cable galleries/ Cable vaults at various levels of TG building are provided with spray system. 3. Fire detection system for Cable galleries/ Cable vaults shall consist photoelectric type smoke detectors. 4. A single run of LHS cable shall also provided running along top, bottom and alternate length of intermediate cable trays. Transfer points in CHP Area: 1. Transfer point Spray system is designed with a density of 10.2 lpm/Sq.m 2. Transfer points at various levels are provided with spray System. 3. Fire detection system for Cable vaults shall Digital LHS Cables.

OPERATION AND MAINTENANCE MANUAL 4.1.4. Manual MVWS System A. LDO/HFO Storage tank: Manual M.V.W.S System is provided for LDO Storage tanks. Manual activated spray system is provided to cool down the tank wall and roof against excessive heat and isolate it from other nearby tanks under fire situation with a water application shall be minimum 10.2 LPM/ m2.Spray systems are provided with spray rings around the tank circumference complete with open spray nozzles, piping, valves and supports. 4.1.5 Fixed Foam System: 1. Foam protection systems are based on the principal of blanketing the burning surface of oil stored inside the tanks by pouring foam mixed with water, enabling to cut - off the oxygen to the burning fuel thus achieving immediate extinguishment of fire. 2. The foam protection systems and their components shall be designed as per NFPA recommendations. 3. Foam protection system for each tank shall have one riser with foam chamber assemblies located near top edge of the tank. 4. Foam application rate shall be minimum 5 lpm / m2 of oil surface area on tank and shall be considered for 30 minutes operation. Oil tanks shall be provided with ROR type heat detectors inside the tank roof for automatic actuation of the foam system and initiating alarm to the local panel as well as main fire panel located in TG Building. Water supply for foam system shall be tapped from the nearest hydrant header.

OPERATION AND MAINTENANCE MANUAL 4.1.6 Portable Fire Extinguisher: In general the extinguishers shall be provided based on the rules specified in TAC hydrant manual.

Sl. No. Type 01 02 03 04 CO2 Fire Extinguishers Dry chemical type Extinguisher Foam type Extinguisher Gas Expelled Water type Extinguisher

Capacity 4.5,5Kgs. 5,25,50 Kgs. 9,50Ltrs. 9 Ltrs

OPERATION AND MAINTENANCE MANUAL 4.1.8 Fire Detection and Alarm System The Fire Alarm Panel (Esser-FLEX ES(FX18)) is of Addressable type. The Detection and Manual call points located at various places are connected to the Fire Alarm Panel by the way of Flexible and Armored Control Cables. In case of any of the Detector/ Manual Call Points being actuated, a signal is transmitted to the Fire Panel which in turn actuate an Audio/visual alarm in the panel, and the external hooters located at various places will be sounded. Fire alarm panel shall be provided with battery, complete with automatic boost cum float charging facility. A 240V AC supply shall be provided to panel. The batteries shall be capable of maintaining the complete system in satisfactory operation for at least 24 hours in the event of AC supply failure. Manual call points shall be located at strategic locations as per TAC. Their design shall comply with IS 2189. A hammer also shall be provided adjacent to each manual call point to facilitate breaking of the frangible top cover. The detectors to be used in FDA system:1. Smoke detectors, conforming to IS : 11360 2. Heat detectors, both fixed type and rate of rise type, conforming to IS: 2175 3. Infra red ember detectors 4. Three runs of LHS cable shall be provided running all along the conveyor to cover top, bottom belt and roller etc. 5. Choice of a particular type of detector for protected areas shall be guided by TAC.

OPERATION AND MAINTENANCE MANUAL

5. SYSTEM OPERATION

OPERATION AND MAINTENANCE MANUAL

5. SYSTEM OPERATION
5.1 HYDRO-PNEUMATIC TANK The hydrant and spray system is always kept pressurized, devoid of airlock, by combination of Jockey Pump, Hydro pneumatic tank and Air Compressor. The capacity of the Hydro pneumatic (HP) tank is 15CU.M and The Capacity of the compressor is 250L. The Hydro pneumatic (HP) tank is filled with 2/3 volume of water and 1/3 volume of air. Delivery of Jockey Pump is connected to Hydro pneumatic tank by non-return and isolation Valve. The Compressor maintains the pressure in Hydro pneumatic tank. Outlet of water is taken from bottom of tank and connected to main delivery header of hydrant system & spray system. The Jockey pump is used to maintain the water level in the Hydro Pneumatic tank. When the water level in the Hydro Pneumatic tank falls due to minor system leakages, the jockey pump will start and fill the tank. Level switches installed on Hydro-pneumatic tank control Starting/stopping of Jockey Pump. The low-level condition starts jockey pump. When desired water level is reached, the jockey pump stops. During initial filling of the Hydro-pneumatic tank, the Jockey Pump (main) will start and fill up water upto 2/3 volume at atmosphere pressure. The air

compressorwill run start, raising the pressure in tank from atmosphere to 10.5 Kg/cm2(g).During normal working condition, when water level falls in the Hydro-pneumatic tank due to minor leakages, low-level switch (LSL-1) will send a signal to CCAP. In turn CCAP will send a signal to start main jockey pump (JPP-1). Main jockey pump will run to fill water to HP tank. Due to some problem, if the main jockey pump is fail to start, water level will fall further and when the level reaches low-low-level switch (LSL-2) will actuate to start the second jockey pump (JPP-2).

OPERATION AND MAINTENANCE MANUAL However stopping of both the jockey pumps will be attained by high-level switch (LSL-3), automatically.Main and standby compressors are provided to compensate the minor air leakages. Due to minor air leakages, if the pressure is dropped below 9.5 Kg/cm2(g) air compressor will start and stop at 10.5 kg/cm2(g) automatically.If any of the main pumps started, jockey pump shall be tripped automatically(This sequence shall be incorporated in the MCC) 5.2 FIRE PUMP Starting Hydrant, Spray and Diesel Engine stand by pumps are controlled through the pressure switches fitted in the hydrant and spray system headers. Starting and stopping of jockey pumps are controlled through level switches fitted in the hydro-pneumatic tank. 5.2.1. HYDRANT SYSTEM When any of the hydrant valves in the field is opened, the water pressure in the corresponding water pipe lines shall fall rapidly. Capacity of the hydropneumatic tank and jockey pump shall not be sufficient to meet the large requirement. As a result, the pressure in the hydrant line will fall further and impulse from pressure switch in the hydrant main shall start the Motor driven hydrant pump (HPP-1) at 8.5 Kg/cm2(g). Failure to start pump on demand will result in further fall in header pressure or if the header pressure still falls even when one pump is running then the second motor driven main pump (HPP-2) will start at 7.5 Kg/cm2(g). A third, Diesel Engine driven main pump (HPP-3) will come into operation when the demand is even more at 6.5 Kg/cm2(g). In addition to the above pumps, a Diesel Engine driven stand-by pump (HPP-4) is also provided to cater the water requirement incase of failure of all or one of the main pumps at 5.5 Kg/cm2(g).Thus, an automatic sequential starting of pumps will be proved with a status indication in the control panel. Pumps can be started manually in case of emergency. However pumps can be stopped only manually from the control panel.

OPERATION AND MAINTENANCE MANUAL 5.2.2. SPRAY SYSTEM

Normally both spray system and hydrant system headers will remain charged with water at the desired pressure of 10.5 Kg / cm2(g). On detection of fire, the automatic actuation of deluge valve decreases pressure in spray pipeline. Capacity of the hydro-pneumatic tank and jockey pump shall not be sufficient to meet the large requirement. As a result, the pressure in the spray line will fall further and impulse from pressure switch in the spray main shall start the Motor driven Hydrant pump at 8.5 Kg / cm2(g).

Failure to start the pump on demand will result in further fall of header pressure or if the header pressure still falls when spray pump is running then the signal from pressure switch will actuate the stand by diesel engine driven pump to start automatically at 7.5 Kg / cm2(g). In the event of failure of stand by diesel engine driven pump to start, the header pressure will fall further and sequentially, the header non-return valve will allow water from hydrant header to spray header. This will decrease the pressure in hydrant header resulting in starting of hydrant pumps as explained in 4.2.1 to cater the spray system. As because of the non return valve in the header, water will never flow from spray system to hydrant system.

5.2.3 Manual operation Pumps can be started manually in case of emergency by pressing the push button in the control cum annunciation panel. However, pumps can be stopped only manually.

OPERATION AND MAINTENANCE MANUAL 5.3 Hydrant system

5.3.1 Operation of hydrant valve

Open the nearest hose box with the key provided. If the key is missing then break the glass door. Take the hose with coupling and branch pipes with nozzle from the hose box. Connect two hoses using hose coupling. Connect the branch pipe with nozzle to one end of hose having female coupling. Connect the other end of hose with male coupling to the hydrant valve. Hold the hosepipe with branch pipe and nozzle properly. Open the hydrant valve gradually. Play the water jet towards the seat of fire.

5.3.2 Operation of Water Monitor Release the lock nut for vertical movement of the monitor nozzle. Adjust the jet towards the fire vertically and lock it. Release the horizontal movement lock nut if required. Adjust the jet towards the fire horizontally and lock it. Open the Isolation valve provided in the monitor gradually. After the valve is opened, if the water is not playing on the seat of fire, adjust the horizontal and vertical locks to direct the water towards the seat of fire. 5.3.3 Operation of Fire Escape Hydrant Repeat the procedure as explained for hydrant valve.

OPERATION AND MAINTENANCE MANUAL 5.4 Spray System All the spray systems provided in the plant are of automatic type and does not require any manual intervention for the operation. Incase of failure in the automatic detection system, manual overriding will be required. 5.4.1 Automatic operation Incase of fire, in HVWS system, the rapid rise in temperature will cause the liquid inside the fragile glass bulb (Quartzoid bulb) will expand. Since the coefficient of expansion of the liquid is very high, it will cause the glass bulb to shatter & the water under pressure will escape. In MVWS system, LHS cables will sense the fire and sends the signal to FACP and in turn FACP will send a signal to open the solenoid valve of deluge valve. As a result of the above, the pressure in the detection network will fall and the diaphragm of the Deluge valve will rise.

Because of the rise of the diaphragm of the Deluge Valve, the water will be flowing through the spray network and projectors will spray the water to the Transformer. Due to the pressure drop in the spray network, the pump will start. 5.4.2 Manual operation In case of fire, if the detection system fails and visually fire is detected, open the deluge valve by one of the following methods manually. Open the emergency release release valve near the deluge valve.

OPERATION AND MAINTENANCE MANUAL 5.5 Foam System Incase of fire, in LDO or HFO storage tank, Probe type heat detectors installed on the tank roof will sense the fire and sends the signal to FACP and in turn FACP will send a signal to open the solenoid valve of deluge valve.As a result of the above, deluge valve will be opened and water will be flowing through. This water will further flow through the inline inductor, which will suck the foam concentrate. Water will mix with the foam concentrate to form a foam solution, which will further travel to foam chamber. Foam chamber has got an inbuilt foam maker which will produce foam and dump to the tank fuel surface. 5.7 Fire Detection and Alarm System As the system is totally automatic in operation, manual intervention to operate the system is not required and only the system has to be reset for normal operation after a fire condition. Fire detection and alarm system operation can be classified in to two types. 5.7.1 Automatic operation In Automatic Fire Alarm System, different types of Fire Detectors located at the various locations are connected to the Fire Alarm Control Panel through cables. During fire condition, the detectors will sense the fire and report it to the panel and does the necessary alarm (in panel and the field). 5.7.2 Manual operation In Manual Operation, during fire, the Manual Call Points "BREAK GLASS" has to be broken to initiate the alarm on the panel and the panel will do all the alarm, annunciation and controls. To reset the system for normal operation, "BREAK GLASS of the Manual Call Point has to be replaced and the panel has to be reset through Reset Push Button.Purpose of this manual call points is to inform the panel about the fire condition when the fire is detected manually. Just by pressing the manual call point, the signal can be transferred to the panel. All the other operations of the panel shall be same as of automatic operation.When the manual call point is pressed the panel display unit will display the exact location of manual call point, so that the operator can identify the location and can take appropriate action to extinguish the fire.

OPERATION AND MAINTENANCE MANUAL

6. COMMISSIONING PROCEDURE

OPERATION AND MAINTENANCE MANUAL

6. COMMISSIONING PROCEDURE
6.1 Hydrant System: A. Keep all the isolation valves and hydrant valves in open condition. B. Start the pump and allow the water to flow freely till clear water flows through the hydrant valves. C. Keep all the hydrant valves closed except the remotest hydrant valve. D. continue to run the main pump to fill the underground pipelines. E. Allow water to flow freely in the remotest hydrant valve and then close the hydrant valve. F. Stop the pump when the pressure in the system attains 8.8kg/cm2. G. Keep all the pumps starting in Auto mode. 6.2 Spray System 6.2.1 H.V.W.S. System: A. Keep all the isolation valves in open condition, except the by-pass valve. B. Break the glass in any one of the Quartzoid Bulb detectors. C. Allow water to discharge through all the H.V.W.S. Projectors. D. Keep all the isolation valves (Upstream & down stream of Deluge Valve Assembly) closed so that the system pressure will be re-stored. E. Open the upstream and downstream line isolation valves. F. Stop the pump manually when the pressure in the system attains 8.8kg/cm2. G. Keep all the pumps starting in Auto mode. H. Keep all the pumps in Auto mode.

OPERATION AND MAINTENANCE MANUAL 6.2.2 M.V.W.S. System: A. Keep all the isolation valves in open condition, except the by-pass valve. B. Open the manual release lever. C. Allow water to discharge through all the M.V.W.S. Sprayers. D. Keep all the isolation valves (Upstream & down stream of Deluge Valve Assembly) closed. So that the system pressure will be restored. E. Open the upstream and downstream line isolation valves. F. Stop the pump manually when the pressure in the system attains 8.8kg/cm2. G. Keep all the pumps starting in Auto mode. H. Keep all the pumps in Auto mode. 6.3 Foam System A. Keep all the isolation valves in open condition, except the by-pass valve. B. Activate the solenoid valve of deluge valve. C. Allow water mixed with Foam to discharge through pipeline via Foam Chamber. D. Keep all the isolation valves (Upstream & down stream of Deluge Valve Assembly) closed so that the system pressure will be re-stored. E. Open the upstream and downstream line isolation valves. F. Stop the pump manually when the pressure in the system attains 8.8 kg/cm2. G. Keep all the pumps starting in Auto mode H. Keep all the pumps in Auto mode.

OPERATION AND MAINTENANCE MANUAL 6.4 Fire Detection and Alarm System Entire installation shall be tested to ensure that it operates satisfactorily & that, A. All Detectors and Manual Call Points function correctly. B. All ancillary equipments functions correctly.
6.4.1 Smoke Detectors / Heat Detectors:

1.

Create a Smoke / Heat by using any reliable source near to the smoke / Heat Detector.

2. 3. 4. 5. 6.

After sometime, observe the alarm in the corresponding panel The fire signal will be transferred to Fire Alarm Control Panel. Observe the Area name of the respected area of fire. Observe the sound of the corresponding Hooter. By pressing Alarm Silenced Push button in the panel, the respected area hooter will be silenced. After completion of testing, press Reset Push Button to restore the panel to Normal condition.

7.

6.4.2 Manual Call Point:

1. 2. 3. 4. 5. 6.

Remove the Manual Call Point glass. Observe the alarm in the Fire Alarm Control Panel The fire signal will be transferred to main Fire Alarm Panel Observe the Area name of the respected area of fire. Observe the sound of the corresponding Hooter. By pressing Alarm Silence Push button in the panel, the respected area hooter will be silenced. After completion of testing, press, Reset Push Button to restore the panel to normal Condition.

7.

OPERATION AND MAINTENANCE MANUAL

7. ROUTINE TESTING

OPERATION AND MAINTENANCE MANUAL

7. ROUTINE TESTING
Even though the system is well designed and well installed, it is very much essential that the system is tested in a routine and maintained properly. It is

desired to operate the system in automatic mode, as its need in an event of fire cannot be neglected. However, manual starting should not be ignored. To maintain both automatic and manual operating to keep intact, routine testing is vital. 7.1 Hydrant System It is recommended to carryout wet-drill once in a week at different hydrant points and monitor. This will have a check on all sections and will prevent settling of mud at valve seats and in pipes. It will also confirm that sectionalizing sluice valves are all open. After extinguishments of fire (or) wet drill, when the load is withdrawn, engine should be run idle for 10/15 minutes. Engine then can be stopped and kept in Auto mode. Stop Push button should be kept pressed until the engine comes to complete halt otherwise it may reaccelerate on its own, even at a very low speed of 15% of the rated speed. 7.2 Water Spray system It shall be ensured that the system is pressurized always. Once in a week, the test cock of the deluge valve assembly should be opened to simulate the operation. Actuating the manual pull switch will operate the spray system. During the spray discharge, it should be checked. i) Whether the alarm is working. ii) Whether any nozzles are blocked. If required, remedial action should be taken.

OPERATION AND MAINTENANCE MANUAL 7.3 Foam System

7.3.1 Foam-Producing Equipment.

A. Proportioning devices, their accessory equipment, and foam makers shall be inspected.
7.3.2 Foam Concentrate.

A. At least annually, an inspection shall be made of foam concentrates and their tanks or storage containers for evidence of excessive sludging or deterioration. B. Samples of concentrates shall be sent to the manufacturer or qualified laboratory for quality condition testing. C. Quantity of concentrate in storage shall meet design requirements, and tanks or containers shall normally be kept full, with space allowed for expansion. 7.4 Extinguishers 1. Examine Extinguisher body externally. 2. Weigh the Extinguisher, Compare mass against the mass marked on it for fully, if the loss is more than 10% refill the cylinder. 3. Examine Hose/Horn Assembly. 7.5 Fire Detection and Alarm System 1. Healthiness of the detector shall be checked visually by seeing the LED glowing. 2. Every week the battery should be checked for the charge availability. 3. Daily, Panel display shall be checked for any event happenings. If there is any fault the same should be attended immediately to rectify the same.

OPERATION AND MAINTENANCE MANUAL

8. MAINTENANCE CHART

OPERATION AND MAINTENANCE MANUAL

8. MAINTENANCE CHART
The system requires a simple day-to-day maintenance. Before taking up maintenance work, notify the authorities that the system is undergoing maintenance. All persons who might receive an alarm signal should be notified in advance to avoid unnecessary response. A. Maintenance of hydrant valves
8.1 Routine Maintenance 8.1.1 8.1.2 Physical checking & Polishing of brass parts Painting of stand posts Weekly Annually

B. Maintenance of Hose pipes & Nozzles

8.2 Routine Maintenance 8.2.1 8.2.2 8.2.3 8.2.4 Hose boxes/Hose stations to be inspected externally Cleaning of Hose boxes/ Hose stations internally & externally Polishing of hose couplings / branch pipes Washing of hose pipes in clean water & drying Weekly Monthly Fortnightly After each use

OPERATION AND MAINTENANCE MANUAL C. Maintenance of Fire Extinguishers

8.3 Routine maintenance
8.3.1 8.3.2 8.3.3 8.3.4 8.3.5 8.3.6 8.3.7 8.3.8 8.3.9 8.3.10 8.3.11 8.3.12 Check all moving parts are Working properly Check the nozzle is not obstructed Check for leakage of extinguishing medium from the glands and nozzle Polish brass parts Clean superficially Weigh gas cartridges, if there loss of more than 10% of original mass, send it for clogging Grease the cap threads and plunger Check the vent holes for clogging Check the sealing washer & replace if necessary Operation test- half the number of water type Extinguishers Operation test- half the number of dry powder Extinguishers Examine the inside surface of the cylinder for condition of plating, rusting. Monthly Monthly Monthly Monthly Monthly Monthly Monthly Monthly Monthly Annually Annually Annually

8.4 Refilling schedule

8.4.1 8.4.2 8.4.3 CO2 Fire Extinguishers Dry chemical type Foam type Fire extinguishers As and when due As and when due As and when due

8.5 Schedule of hydraulic pressure testing of extinguishers

SI.No. 8.5.1 8.5.2 8.5.3 Note: Extinguishers found leaking (or) distorted in the Hydraulic pressure test shall be rejected and discarded. Under no circumstances such extinguishers be welded / repaid and re used. Type of Extinguisher CO2 type Dry chemical type Foam type Test interval 3 Years 3 Years 3 Years Test pressure 17.5 kg/cm2 35 kg/cm2 35 kg/cm2 Duration 2.5 Minutes 30 Seconds 3 Minutes

OPERATION AND MAINTENANCE MANUAL 4. Maintenance of Fire Alarm system

8.6 Maintenance schedule
SI.No: Component Visual Inspection Testing

8.6.1 Control equipment a) Functions b) Fuses c) Lamps and LEDs Primary (main) power d) supply Secondary power e) supply 8.6.2 Batteries a) Charger test b) Load voltage test c) Specific gravity

Weekly Weekly Weekly Weekly -

For every six months For every six months For every six months For every six months For every six months For every six months For every six months For every six months

OPERATION AND MAINTENANCE MANUAL

8.7 Maintenance Procedures

SI. No Device Method

8.7.1 Control equipment Verification of proper receipt of alarm, supervisory and trouble signals, circuit supervisory including Functions detection of open circuits and short circuits, and power supply supervision for detection of loss of AC power and disconnection of secondary batteries Fuses Remove fuse and verify for accurate rating. Operate Lamp test switch and verify whether lamps / Lamps and LEDs LEDs illuminates. Secondary (standby) power supply shall be disconnected Primary (main) Power and tested under maximum load, including of all alarm supply appliances requiring of simultaneous operation it shall be reconnected at the end of test. Disconnect primary (main) power supply and verify Secondary (standby) required trouble indication for loss of power occurs. power supply Operate general alarm systems for a minimum of 5 min. Reconnect primary power supply at the end of test.

a)

b) c) d)

e)

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9. TECHNICAL DATASHEETS

OPERATION AND MAINTENANCE MANUAL 9. DATASHEETS 9.1 DATASHEETS 1. Main Pump (motor & Engine driven) 2. Jockey Pump 3. Motor (main Pump) 4. Motor (jockey Pump) 5. Motor (Booster Pump) 6. Diesel Engine (main Pump & Booster Pump) 7. Gate Valve 8. Non return Valve 9. Pressure Gauge 10. Pressure Switch 11. Hydrant Valve 12.Water monitor 13.Deluge Valve 14. Spray Nozzles 15. Main Fire Alarm panel 16. Sub Fire Alarm Panel 17. Repeater panel 18. Gas release panel 19. Deluge valve control panel 20. Smoke detectors 21. Heat detectors 22. Probe type Heat detectors 23. Infra red detectors 24. Linear Heat Sensing Cable 25. Control Cables 26. Extinguishers 27. Foam System Components