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PRINTING PLANTS
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7-96 Printing Plants
Page 2 FM Global Property Loss Prevention Data Sheets
List of Figures
Fig. 1. Press room design and layout ........................................................................................................... 4
Fig. 2. Rotogravure press fed by piping from storage/mixing room to press sump ..................................... 5
Fig. 3. Solvent dispensing station .................................................................................................................. 6
Fig. 4. In-process storage of paste ink in small containers, metal tote tanks, and metal tanks .................. 7
Fig. 5a. Automatic sprinkler protection for shielded areas of a single level newspaper press ................... 10
Fig. 5b. In-press automatic sprinkler protection for a multilevel newspaper press ..................................... 11
Fig. 6. Carbon dioxide and automatic sprinkler system protection for a rotogravure press using
ignitable inks ...................................................................................................................................... 13
Fig. 7. Carbon dioxide and automatic sprinkler system protection for a central impression (CI)
flexography press with eight printing decks using ignitable inks .......................................................... 14
Fig. 8. Carbon dioxide and automatic sprinkler system protection for a stack-type flexography
press using ignitable inks .................................................................................................................. 14
Fig. 9. Carbon dioxide protection for a six-color, in-line flexograph press using ignitable inks .................. 15
Fig. 10. Typical exhaust system design for rotogravure press with recirculated dryer atmosphere
into burner combustion chamber .................................................................................................... 17
Fig. 11. Areas where Class I, Div 1 and 2 classified electrical equipment is needed for a flexography
press using low-flash point ignitable inks ........................................................................................ 20
Fig. 12. Areas where Class I, Div 1 and 2 classified electrical equipment is needed for a
rotogravure press using low-flash point inks e .............................................................................. 20
1.0 SCOPE
This data sheet contains fire protection and fire prevention recommendations for printing plants.
1.1 Changes
April 2012. This data sheet has been revised to eliminate a conflict that existed with Data Sheets 6-9, Ovens
and Dryers, and 6-11, Fume Incinerators. Changes include the following:
1. The advice in Section 2.4 regarding the need for ventilation and LEL detectors was rewritten to align with
Data Sheets 6-9 and 6-11.
2. Instructions to refer to Data Sheets 6-9 and 6-11 were added where appropriate to avoid creating poten-
tial future conflicts.
B. Install and arrange dust collection systems designed to prevent any dust accumulation inside plant
areas in accordance with Data Sheet 7-73, Dust Collectors and Collection Systems. Always locate dust col-
lection equipment (e.g., cyclones, bag collectors, etc.) outside. Provide adequate explosion isolation
between the dust collection equipment and the building.
C. Provide automatic sprinkler protection in bag-type dust collectors.
D. If a dust collector is located inside, provide damage-limiting construction designed to direct the prod-
ucts of a deflagration (i.e., fire, pressure, and unburned dust) outside the plant or use a properly designed
and installed FM Approved explosion-venting system.
E. Provide building designs that minimize horizontal surfaces where dust can accumulate.
2.2 Occupancy
F. Ensure the transfer system is properly bonded and grounded per Data Sheet 5-8, Static Electricity.
Fig. 2. Rotogravure press fed by piping from storage/mixing room to press sump
2.2.1.2 In cases where more than 55 gal (208 L) of solvent is needed at a press for normal operations, hard-
pipe solvent from a properly arranged cut-off room or tank per Section 2.2.1.1 to the point of use on the
press, and arrange in accordance with Data Sheet 7-32. In cases where manual handling is needed, arrange
the solvent dispensing stations as follows (see Fig. 3):
A. Locate the dispensing station at least 15 ft (4.6 m) from a press, and 25 ft (7.6 m) from any in-process
storage.
B. Design the system to use the minimum flow rate necessary for normal operations, but do not exceed
1 gpm (3.7 L/min) and 1⁄2 in. (13 mm) diameter pipe/tubing.
C. Provide containment at the dispensing point and design it to hold at least 20 gal (76 L) of solvent.
D. In addition to the safety shut-off valve at the point of use, provide an FM Approved, normally closed,
spring-loaded valve at the dispensing point for regular dispensing operations.
E. Provide mechanical, low-level ventilation adjacent to the dispensing point and design it to keep any flam-
mable vapor concentration below 25% of the solvent’s lower explosive limit (LEL).
F. Provide properly arranged bonding and grounding in accordance with Data Sheet 5-8, Static Electric-
ity.
2.2.1.3 Do not store or dispense inks or solvents in storage areas (roll paper warehouse, signature storage
areas, etc.).
Fig. 4. In-process storage of paste ink in small containers, metal tote tanks, and metal tanks
2.3 Protection
2.3.1 General
2.3.1.1 Install wet automatic sprinklers throughout printing press facilities. Extra care needs to be taken to
ensure all concealed spaces with combustible materials around presses or below mezzanines are adequately
covered by sprinkler protection.
2.3.1.2 Design automatic sprinkler systems as follows:
A. Design ceiling sprinkler protection for press rooms with no in-process storage to provide a
0.30 gpm/ft2 (12 mm/min) over 3,000 ft2 (279 m2) using 165°F (74°C), quick-response sprinklers.
B. Design ceiling sprinkler protection for press rooms with limited quantities of in-process storage as
described in Sections 2.1.2(B), 2.1.2(C), and 2.2.2 to provide a 0.30 gpm/ft2 (12 mm/min) over 3,000 ft2
(279 m2) using 286°F (141°C) sprinklers.
C. Design ceiling sprinkler protection for press rooms with excess amounts of in-process storage of roll
stock or ignitable liquids in accordance with the appropriate data sheet. Protect the entire press room area
for the highest hazard.
D. Protect paste-ink storage and staging as follows (see Figure 4):
1. Design ceiling sprinklers over small container storage (not more than 6.5 gal [25 L]) of paste inks in
accordance with Data Sheet 8-9 using the protection criteria for a cartoned unexpanded plastic.
2. Design ceiling sprinklers over metal tote storage to provide at least a 0.30 gpm/ft2 (12 mm/min) over
2,000 ft2 (186 m2) using 165°F (73°C) sprinklers.
C. Provide in-rack sprinklers over the first tier of a tote storage rack using a horizontal spacing of 8 ft
(2.4 m) located at each rack upright. Use quick-response, K ≥ 5.6 (80), 165°F (73°C) automatic in-rack
sprinklers. Design for operation of up to eight sprinklers at a flow rate of 30 gpm (115 L/min) and balance
with the provided ceiling sprinkler system.
2.3.1.3 Interlock the following press systems to automatically shut down upon activation of a fire protection
system:
• Ink, solvent, thinner, and blanket wash pumping systems
• Vacuum systems
• Hydraulic oil systems
• Lube oil systems
• Pneumatic systems
In addition to the automatic interlocks, provide a remotely accessible manual shut-off.
temperature in the areas where the sprinklers will be installed and ensure the temperature rating of the
sprinklers is at least 50° above ambient).
2.3.2.3 Provide one of the following types of fixed fire protection for multiple-unit-high (tower) presses as
follows:
A. Provide automatic sprinkler protection below platforms, catwalks, and in archways.
1. Provide automatic sprinklers for multilevel presses at all operating levels as described in Sections
2.3.2.2(A) through 2.3.2.2(D).
2. Provide 165°F (74°C) quick-response automatic sprinklers to protect all archways (doghouses) of
press towers to limit vertical fire spread.
3. Design in-press sprinkler protection for 14 sprinklers (seven sprinklers on each of two levels)
operating at 22 gpm (83 L/min). Use K ≥ 5.6 (80), quick response, 165°F (74°C) sprinklers. In-press
sprinklers do not need to be balanced with ceiling sprinklers (consider the ambient temperature in the
areas where sprinklers will be installed and ensure the temperature rating of the sprinklers is at least
50° above ambient).
B. Provide an automatic fixed water spray system designed as follows:
1. Arrange FM Approved open nozzles around each press level, with the nozzles pointed into press
openings.
Fig. 5a. Automatic sprinkler protection for shielded areas of a single level newspaper press (not shown is automatic sprinkler
protection for shielded areas on the opposite side of the press); for multiple press levels the protection shown above is
repeated at each level of the press
Fig. 5b. In-press automatic sprinkler protection for a multilevel newspaper press
2. Design the water spray system to provide 22 gpm (85 L/min) with a minimum discharge pressure
of 7 psig (0.5 barg) using solid cone, spray nozzles with a maximum discharge angle of 120°. The deluge
system does not need to be balanced with the ceiling sprinkler system.
3. Provide a separate deluge valve for each tower tied to a heat detection system located above that
tower, or use automatic zone valves tied to a heat-detection system located above a tower and a single
deluge valve.
4. Provide a water supply adequate for the water-spray systems in two adjacent towers.
2.3.2.4 Use a cage around any installed sprinklers if there is a possibility that mechanical damage could
result in their operation.
2.3.2.5 When used, install pre-action automatic sprinkler systems in accordance with Data Sheet 2-0,
Installation Guidelines for Automatic Sprinkler Systems. Ideally, use line-type heat detection wrapped around
the sprinkler piping, or use spot heat detectors located no more than 12 in. (30.5 cm) from each automatic
sprinkler to ensure prompt water delivery. Usually, pre-action sprinkler systems are not recommended or
needed for this occupancy.
Fig. 6. Carbon dioxide and automatic sprinkler system protection for a rotogravure press using ignitable inks
Fig. 7. Carbon dioxide and automatic sprinkler system protection for a central impression (CI) flexography press with eight
printing decks using ignitable inks
Fig. 8. Carbon dioxide and automatic sprinkler system protection for a stack-type flexography press using ignitable inks
Fig. 9. Carbon dioxide protection for a six-color, in-line flexograph press using ignitable inks (where the press is in an
enclosure, sprinklers would be provided within the enclosure)
2.3.9 Ducts
2.3.9.1 Design, construct, and protect ducts in accordance with Data Sheet 7-78, Industrial Exhaust Systems.
Provide automatic sprinkler protection for metal ducts if there are accumulations of oily residue and paper
dust. Inspect ducts every six months.
2.4.1 General
2.4.1.1 Provide hard-wired safety circuits, or install PLCs or other programmable electronic systems in
accordance with Data Sheet 7-45, Instrumentation and Control in Safety Applications.
2.4.1.2 Provide low-level local ventilation for rotogravure and flexograph presses using low-flashpoint inks
for normal operation and when shut down for cleaning. Ensure ventilation rates are 1 cfm/ft2 (0.3 m3/min m2).
Extend ventilation to cover dispensing of liquids with flashpoints lower than 200°F (93°C). Provide supervision
for the ventilation and alarm on loss of ventilation.
Fig. 10. Typical exhaust system design for rotogravure press with recirculated dryer atmosphere into burner combustion
chamber; the figure shows LFL detectors for the dryer, explosion venting for the dryer and ductwork, and damper
arrangement set for minimum exhaust ventilation based on ink application rate or auto solvent wash, whichever is greater
E. Ensure the oxidizer is in operation before dryers are purged and the startup cycle is initiated.
F. Shut off the burner for the dryers and stop the press imprint roller and web if the thermal oxidizer trips.
2.4.2.9 Do the following where press designs allow modification of re-circulation rates for the dryers:
A. Verify there has been no change in safety monitoring interlocks (air flow, air pressure switches, damper
proximity switches) following a modification of recirculation rate.
B. Develop a formal procedure to confirm the change in recirculation rate will not result in hazardous vapor
concentrations in the dryer and associated ductwork.
2.4.2.10 Provide a direct method of measuring exhaust ventilation from the oven, or interlock the damper
system with a proximity switch set at the minimum exhaust air flow rate for the dryer.
2.4.2.11 Interlock direct-fired dryers (or dryers that operate at a temperature high enough to ignite the printed
material) to shut down when the press is stopped. For rotary web press, the web could be automatically
removed on press shutdown.
2.5 Maintenance
2.5.1 Clean and test the static eliminator system periodically.
2.5.2 Establish a formal preventive and predictive maintenance program for press unit bearings, drive motors,
clutches, gearboxes, dryer fans, and combustion blowers.
2.5.3 Establish a formal preventive maintenance and testing program for all fuel-fired equipment burner safety
controls.
2.5.4 Establish a formal preventive maintenance, testing, and calibration program for LFL detection systems
and interlocks on press dryers and thermal oxidizer units in accordance with OEM specifications.
2.5.5 Maintain dryers and thermal oxidizing equipment in accordance with OEM specifications and Data
Sheets 6-9, Industrial Ovens and Dryers, and 6-11, Fume Incinerators.
2.6.3 Housekeeping
2.6.3.1 Keep equipment that generates combustible dust, such as paper and starch, and the surrounding
areas as dust-free as possible using automatic dust-collection equipment. In the event of an accidental dust
release, only use vacuuming for cleaning up the dust. (See Data Sheet 7-73, Dust Collectors and Collection
Systems, for further protection guidelines.)
2.6.3.2 Establish cleaning schedules for (a) presses, (b) ink troughs, (c) folders, (d) dryers, (e) slitters, (f)
dust collection ducts, (g) baler rooms, (h) areas below the press, and (i) oil-collection pans.
2.6.3.3 Do not allow continuous residue accumulations between press units of greater than 1/16 in. (1.6 mm)
high-density dust to 1⁄8 in. (3.2 mm) low-density dust above or below the press operating floor. Record
cleaning frequencies.
2.6.3.4 Prevent the accumulation of paper scrap, ignitable liquids, and cleaning rags.
2.6.3.5 Examine ducts, areas above suspended ceilings, and all pit areas at least every six months for
accumulations of ink mist. Clean as necessary. Redesign of the ventilation system may be needed where
frequent cleaning is required.
Fig. 11. Areas where Class I, Div 1 and 2 classified electrical equipment is needed for a flexography press using low-flash
point ignitable inks
Fig. 12. Areas where Class I, Div 1 and 2 classified electrical equipment is needed for a rotogravure press using low-flash
point inks, and where Class II, Div 2 classified electrical equipment is needed within and below the folder sound enclosure
2.7.5 Observe standard ignition-source prevention practices with regard to hot work and smoking.
3.1 Construction/Location
3.2 Occupancy
3.3 Protection
3.4 Maintenance
There are two types of maintenance for presses: preventive and predictive.
Preventive maintenance consists of regularly scheduled tests, measurements, adjustments, and parts
replacement performed specifically to prevent faults from occurring.
Predictive maintenance is condition-driven. Oil changes and sump cleaning are conducted as described
above; however, rather than replacing the bearing on a regular schedule, instruments are used to monitor
the mechanical condition and other parameters in an attempt to determine the approximate time of failure so
the bearing can be replaced before it fails.
4.0 REFERENCES
4.1 FM Global
Data Sheet 4-1N, Fixed Water Spray Systems for Fire Protection
Data Sheet 4-5, Portable Extinguishers
Data Sheet 5-1, Electrical Equipment in Hazardous Locations
Data Sheet 5-8, Static Electricity
Data Sheet 5-32, Electronic Data Processing Systems
Data Sheet 6-9, Industrial Ovens and Dryers
Data Sheet 6-11, Fume Incinerators
Data Sheet 7-2, Waste Solvent Recovery
Data Sheet 7-29, Ignitable Liquid Storage in Portable Containers
Data Sheet 7-32, Ignitable Liquid Operations
Data Sheet 7-45, Instrumentation and Control in Safety Applications
Data Sheet 7-73, Dust Collectors and Collection Systems
Data Sheet 7-78, Industrial Exhaust Systems
Data Sheet 7-88, Storage Tanks for Ignitable Liquids
Data Sheet 7-98, Hydraulic Fluids
Data Sheet 7-99, Heat Transfer by Organic and Synthetic Fluids
Data Sheet 8-9, Storage of Class 1, 2, 3, 4 and Plastic Commodities
Data Sheet 8-21, Roll Paper Storage
4.2 Other
American National Standards Institute (ANSI). Safety Standard – Printing Press Systems. ANSI B65.1-1995.
American National Standards Institute (ANSI). Binding and Finishing Systems. ANSI B65.2-1999.
Gravure Association of America, Inc. “Gravure Process Glossary.” http://www.gaa.org
National Fire Protection Association (NFPA). Guide for Fire and Explosion Investigation. NFPA 921. Latest
edition.
National Fire Protection Association (NFPA). National Electrical Code. NFPA 70. Latest edition.
Color management:Controlling the matching of colors between an original image, scanner, monitor, color
printer, and final press sheet.
Combustible liquid: See ignitable liquid.
Cylinder: Round, cylindrical copper or chrome-plated roller that carries etched image on the printing press,
revolving in a fountain of ink and being wiped by the doctor blade, prints on the moving web or substrate.
Flat-bed cylinder presses are sheet-fed and used mainly for short-run work such as booklets, folders, catalogs,
and labels. The quality of paper can vary widely from coarse to coated paper. Fine register multicolor work
also may be done, each color requiring a separate printing operation. The maximum press speed is 5,000
impressions per hour.
Ignitable Liquid: Any liquid or liquid mixture that will burn. A liquid is defined as having the ability to burn if
it has a measurable fire point. Ignitable liquids include flammable liquids, combustible liquids, inflammable
liquids, or any other term for a liquid that will burn.
Intermediate bulk container (IBC): Defined by the U.S. Department of Transportation in CFR Title 49, Part
178, Subpart N, dated October 1, 1997, and the United Nations Recommendations on the Transport of
Dangerous Goods, Ninth Edition, Chapter 16. The container size is limited to 3000 L or 793 gal There are no
other specific requirements on the design or material of construction. All IBCs must pass the required
performance-based testing designed to evaluate their resistance to leakage during transport. No existing test
requirements evaluate the container’s performance when exposed to fire. The IBC category also includes
the containers previously defined as portable tanks or tote tanks. Some limitations on the type of liquid storage
allowed in an IBC used for transportation do exist. However, for most commonly transported ignitable liquids,
there are few limitations.
Lacquer: Clear varnish with a plastic film-former base (originally used to denote nitrocellulose-type fast-drying
inks and varnishes).
Laser engraving: The application of image information directly onto a zinc layer by the thermal energy of a
pulsating laser beam. Every laser pulse creates one cell by local evaporation of the zinc material. Because of
the pulse repetition rate of the laser beam, 70,000 cells per second can be generated.
Paste ink: An ink with a closed cup flash point greater than or equal to 200°F (93°C) that in an unsheared
condition at room temperature will not pour or readily flow. There is no definition for paste ink in the printing
industry.
Platen presses: Platen presses are the most flexible type of letterpress, capable of printing on a wide range
of paper products from thin paper to heavy cardboard, and from coarse to high-gloss paper. Fine register
multicolor work can be done, each color requiring a separate printing operation.
Process colors: The four colors (cyan, magenta, yellow, and black) that are controlled to print a wide range
of colors. When blended, these reproduce only a small portion of all the colors found in nature, but they can
reproduce the widest range with the fewest number of inks.
Sealed container: This term refers to a container that is tightly covered. An example is a container that is
ready for shipment versus a container that has a loose fitting cover provided.
Secondary colors:Colors created by combining two primary colorants of a color system (also referred to as
overprint colors). Example: red would be the secondary color produced with magenta and yellow.
Tote Tank: Heavy steel cylindrical tank generally used for paste ink storage, dispensing, and shipping. They
range in size from 200 gal (750 L) to 400 gal (1510 L). The tanks are designed for pressurized dispensing
of paste ink.
Web: Material to be printed and/or processed in roll form.
Web guide: Device that keeps the web traveling straight or true through the press.
2. Instructions to refer to Data Sheets 6-9 and 6-11 were added where appropriate to avoid creating potential
future conflicts.
April 2010. The following changes were made:
1. Separated flammable/combustible liquid protection into three categories: (1) low flash-point (below
200°F [93°C]), (2) high flash-point (200°F [93°C] and above), and (3) paste inks.
2. Added guidance on when to protect a printing occupancy as an flammable/combustible liquid-use
area in accordance with Data Sheet 7-32, Flammable Liquid Operations.
3. Added recommendations for in-process storage of roll paper in the press room.
4. Added recommendations for housekeeping in newspaper offset lithograph press operations.
5. Added details on the location and type of automatic fire protection for single and multiple-level
lithograph presses.
6. Added details on local-application CO2 system installation to promote better understanding of the
system design.
7. Added requirements for proper testing and maintenance of CO2 systems.
8. Added recommendations for control and computer room protection, carbon bed adsorbers, plate
washers, solvent recovery, lube oil, hydraulic, pneumatic, and heat transfer fluid (HTF) systems.
9. Added recommendations for dryers, exhaust ducts, and thermal oxidizers where design variations
for printing plant installations are different than those covered in existing standards.
January 2000. The document was reorganized to provide a consistent format.