Swami Vivekanand University

Fire Training Report

Student Name: Mohd Shariq

Enrollment Number: 12300UITBFS1600007

Department: Department of Fire & Safety

Training Organization: Heavy Water Plant (Department of Atomic Energy)

Training Duration: From 17/04/2018 to 19/05/2018

Date of Report Submission: 22/05/2018

Checked By: (Station Officer)

(Heavy Water Plant Baroda)
(Department of Atomic Energy)
 Contents
1. Declaration-------------------------------------------------------------------------------1
2. Special thanks to------------------------------------------------------------------------2
3. Training Summary----------------------------------------------------------------------3
4. Chapter 1: Company profile and training outline-------------------------------4
1.1 Heavy Water Plant (Baroda)----------------------------------------------------4
1.2 Training Outline--------------------------------------------------------------------5
1.3 Fire Detection----------------------------------------------------------------------5
1.4 Fire hydrants at HWP(B) --------------------------------------------------------5
1.5 Fire tender--------------------------------------------------------------------------6
1.6 Fire water supply system -------------------------------------------------------6
1.7 Water spray system--------------------------------------------------------------6

5. Chapter 2: Practical Training---------------------------------------------------------7

2.1 Fire Station--------------------------------------------------------------------------7
2.2 Potassium Metal Plant-----------------------------------------------------------8
2.3 Tri Butyl Phosphate---------------------------------------------------------------9
2.4 Sodium Metal Plant---------------------------------------------------------------9
2.5 N-Butanol Storage Tank----------------------------------------------------------10
2.6 DM Water Plant----------------------------------------------------10
2.7 Visit to study the working of
High Velocity Water Spray System of plant-------------------------------10
2.8 Laboratory-------------------------------------------------------------------------10
2.9 Project------------------------------------------------------------------------------10

6. Chapter 3: Impact of engineering and learned skills in training-----------11

7. Chapter 4: Conclusion---------------------------------------------------------------12
8. Chapter 5: Remarks------------------------------------------------------------------13
 Declaration

This report is written by Mohd Shariq, a student in

Department of Fire & Safety Engineering at Swami
Vivekanand University, Sagar, (MP). It has not been altered or
corrected as a result of assessment and it may contain errors
and omissions. The views expressed in it together with any
recommendation are those of the student.
Special Thanks to –
1. Mukesh Joshi Sir (Station Officer): For teaching me such a great thing on
fire and rescue technique by giving his valuable time and for helping me in
preparing my project.
2. A.K Singh Sir (Sub- Officer): For teaching me about the working of Plant and
the working of fire suppression system of plant by taking me for the visit of
whole plant.
3. Praveen Bhai Mali Sir, Ashok Bhai Parmar sir, Mahendra Prajapati Sir, Kishor
Bhai Makwana Sir, Akash Sir: For teaching me about the maintenance and
refiling (except CO2) of all types of fire extinguisher.
4. Roshan Barot Sir: For teaching me about the BA-Set, its maintenance and its
refiling.
5. Bhagwati Nath Yogi Sir: For teaching me about working of fire tender and
ultra high power hose reel (UHP).
6. J.P Sir(Training and placement officer SVNU): for providing me such a nice
opportunity.
 Training Summary
 I have completed a 33 days training at Heavy Water Plant (Baroda).
 Heavy Water Plant (Baroda) is a unit under Department of Atomic Energy,
Government of India, that manufactures Heavy Water, Potassium Metal, Sodium
Metal and Tri butyl Phosphate (TBP).
 The work data of such institution is so sensitive that it must have strict security
procedures to protect its products from theft especially by rival countries who will
find this information very useful. These strict procedures have large effect in
limiting available information to include in this report. Only available information
is included.
 Major project that is taking concern in the plant is to manufacture the sodium
metal in a sustained way, and the sodium metal plant is in testing phase and also to
produce deuterium based chemicals which enhances the properties of chemical.
 Academic material information is essential for the work and development of
engineer more than any else job. He/she should remember much of what he/she
studied at university and at the same time learn more and more to keep in track
with new technologies and researches.
 At Heavy Water Plant (Baroda) I stepped large steps in improving my skills and
understanding the fire prevention, firefighting, maintenance of fire appliances and
equipment.
 I learned typical steps for maintenance of fire suppression equipment and their
uses.
 The main and most useful part of my training was working with the fire fighters of
plant.
 During the training period, I was submitted small tasks for preparation of HIRA
(Hazard Identification and Risk Assessment) of various sectors of plant.
 I think that my most important outcome from training in Heavy Water Plant
(Baroda) is acquiring many new useful skills of various types and developing
some of my existing skills. I think these skills are very valuable since they can
signify an impact in solving problems and in development of my career.
 Chapter 1: Company Profile and Training Outline
1.1 Heavy Water Plant (Baroda)

Heavy Water Plant at Baroda is the first plant set up in the

country for the production of heavy water by
employing Mono-thermal Ammonia-Hydrogen exchange
process.
This facility also has a Potassium metal plant for supply of
Potassium metal for preparing catalyst solution for all Mono-
thermal Ammonia-Hydrogen exchange plants.
A Tri Butyl phosphate plant for supply of TBP solution for
refining the nuclear reactor fuel.
And sodium metal plant for supply of sodium metal to use it
as a coolant in nuclear reactor which is in development
phase.

Heavy Water Plant (Baroda) handles phosphorous oxy

chloride, N-Butanol, Calcium carbide, Sodium Carbonate, Tri
Butyl Phosphate, Natural gas, Chlorine etc for the production
of TBP, Calcium Carbide and potassium fluoride for the
production of potassium metal. All these chemicals are
highly hazardous in nature.
 Hazards associated with plant:

 Electrical hazards
 Chemical hazards
 Fire hazards
 Toxic hazards
 Explosion hazards

1.2 Training Outline

- Site Tours
- Maintenance Work
- Fire Equipment Study
- Adequate study of fire protection system of plant

1.3 Fire Detection: Automatic fire detection and alarm system comprising of
smoke and heat detectors, manual call points with telephone sets has been
installed covering all vital areas/location.

1.4 Fire hydrants at HWP(B):

 42 nos of hydrants.
 7 nos of hydrant cum monitor.
 8 nos of fixed monitor.
 Are provided on fire water network. In addition to this 4 nos of platform
type portable monitors and 6 nos of trolley mounted monitors are available
in the plant.
 The fire water network is in the form of ring and parallel routings. To take
care of maintenance without affecting entire network 25 nos of isolation
valves are provided.
1.5 Fire Tender: The fire station of HWP(B) is provided with 2 nos of combined
fire tender and one number of fire jeep.
Capacity:
1. Water: 2250 liters
Foam agent: 450 liters
DCP: 40 Kg
CO2: 90Kg

2. Water: 2450 liters

Foam agent: 450 liters
DCP: 140Kg
CO2: 90Kg

1.6 Fire water supply system:

 Capacity: 68,100 m3
 Electric Motor Driven pump of capacity: 204m3/Hr
 Diesel Driven Pump of capacity: 270m3/HR
 Jockey Pump (3no.) of capacity: 15m3/HR each

1.7 Water Spray System:

 6MVA – Water spray system 2nos one on each transformer.
 2MVA – Water spray system 2 nos one on each transformer.
 1250 KVA – Automatic high velocity water spray system with remote
manual operation.
 70V11/12 – Manual operated (local and remote) medium velocity water
spray system.
 N-Butanol Tank 118V1 – Manual operated water spray system.
 Chapter 2: Practical Training
In the following sections I describe the duties and jobs in detail that were
done by me during the training:

2.1 Fire Station

The fire station of Heavy Water plant Baroda house the large community of
Professional of fire department.
Due to their hard work and effort the employs of the plant works with less
worry about fire hazard.

During training the work done by me are as follows:

1. Maintenance and refiling of fire extinguisher (DCP, FOAM, CO2, WATER)
2. Maintenance and refiling of BA-SET.
3. Study about working of PTO (power take off system) in fire tender.
4. Practical of working of fire tender.
5. Practical and demonstration of working of UHP (ultra high power) hose
reel.
6. Practical study of working of fire alarm panel.
7. The details of the work done by me are given below.
 2.2 Potassium Metal Plant
Potassium metal is produced by thermal reduction of potassium fluoride
and calcium carbide in a batch process. The raw material, calcium carbide
and potassium fluoride are mixed under inert gas atmosphere. The mixed
raw material (charge) are put in to the retort and finally placed in the
natural gas fired furnace after fixing the retort head. The reaction of
formation of potassium metal is endothermic and starts at elevated
temperature. Evolved vapors of potassium metal is cast as rods, cut and
stored under paraffin oil. Potassium metal is used for preparing catalyst
solution of potassium amide for all Mono-thermal Ammonia-Hydrogen
exchange plants. The production capacity of plant is 52 MT/year and has a
capability to meet the demands of external customers also. Plant was
awarded ISO-9001: 2000 on 06.08.2002 and produces the Potassium Metal
of high quality having a purity level of 99.8 % by weight. The consumers of
potassium metal are Baroda, Thal, Hazira and tuticorin division of heavy
water board.

 Hazards of potassium metal plant

The hazards of this plant are due to high temperature of open handling of
calcium carbide and handling of potassium metal, and possibility of
generating hydrogen and acetylene in contact with moisture.

 Chemicals handled
- Calcium carbide
- Potassium fluoride
- Natural gas
- Hydrochloric and sulphuric acid
- Chlorine
2.3 Tri Butyl Phosphate (TBP) plant
The 130 MTPA TBP production facilities at HWP(B) is means for production of
high purity Tri Butyl Phosphate required for rear end of nuclear reactor fuel
cycle. It is an independent unit being operated round the clock shifts. The
plant operation is carried out in batches. The annual capacity is based on
300 operating days and a batch capacity of 1200kgs in two and a half days
of operation. Utilities like cooling water, instrument air, nitrogen, fire, water
and class-1, class-3 and class-4 power supply are also available.

The production of TBP involves mainly four steps as given below:

 Esterification reaction between phosphorous oxy-chloride (pocl3) and

N-Butanol.
 Neutralization of some undesired acidic compounds like HCL and mono
and di-butyl phosphoric acids.
 Butanol recovery.
 Final purification of crude TBP.

2.4 Sodium Metal Plant

Sodium metal production in 2000amps test cell facility:

Basic principle of operation: Operation of the test cell is based on

electrolysis of sodium chloride. Low voltage current will be passed
through the fused sodium chloride in the cell. Sodium gets collected at
the cathode and chlorine gets collected at the anode. Sodium is removed
in the liquid form whereas chlorine comes out from cell as gas. Dry
chlorine from cell will be passed through Alkali (NAOH) scrubber for
converting it to sodium hypochlorite. Sodium metal is currently used as
coolant in thorium powered nuclear reactor instead of heavy water. And
also the produced chlorine gas is utilized by them by manufacturing a
high concentrated caustic (i.e. Sodium hypochlorite). Currently the plant
is in development phase.
Process description: The electrolysis reaction is
2NACL(heat)->2NA(L)+CL2(g)
2.5 N-Butanol Storage Tank
N-Butanol is used in preparation of Tri Butyl Phosphate in TBP plant

2.6 DM Water Plant

This plant demineralizes the water and then supply it to the whole plant.

2.7 Visit to study the working of High Velocity Water Spray

System of plant

I visited three transformers there 02MVA, 06MVA and 1250KVA

which were installed with High Velocity Water Spray System, the
working of the system was explained to me by A.K Singh Sir (Sub-
Officer)

2.8 Laboratory
At Heavy Water Plant Baroda they have a world class chemical laboratory
where they work on mixing the chemicals with Deuterium, to enhances the
properties of chemicals.

2.9 I prepared HIRA/JSA report on potassium metal plant and

N-Butanol Storage tank.
 Chapter 3: Impact of Engineering and Learned Skills in
Training

In practical training you learn how to determine the type and

quantities of fire suppression and to learn the important rule in
Engineers life that does it with lesser cost and higher safety.

Fire & safety Engineering needs the practical practice in field

and it provide us the opportunity to apply all our theoretical
knowledge in to practical and learn from it to be a better
engineer.

In the training period I have experienced engineers work as part

of an extremely significant contribution and learned how to
perform as well as a part of a team.
Fire &safety Engineer requires some sort of interactions with
worker, whether they are working in a team situation, or just
asking for advice, engineers must have the ability to
communicate and work with other people.
 Chapter 4 Conclusion
1. The training is an important course because it closes the gap between the
scientific study and practical study.
2. You get to learn how to deal with others in industry.
3. Finding that team work is the most important element in every successful
project.
4. You get to learn that Fire & Safety engineer is capable of a lot of work
Supervision, implementation, the calculation of quantities and designing the
installation of fire suppression system, and even he/she can work as
consultant.
5. You get to learn how to control and manage the site and how to behave
when problem arises by taking a professional decision.

In fact, my training in Heavy Water Plant was very useful to me in acquiring new
engineering skills that I had not had before. These learned skills prove being very
valuable by signifying an impact in solving problems. It is well known that
engineering skills have vital importance in design problems specifically. Some of
the areas, problems and difficulties in which the engineering skills I learned
signified an impact in solving problems are the following:

 How to suppress the ammonia gas leakage.

 How to suppress the chlorine gas leakage.
 Maintenance and refiling of fire extinguishers.
 Maintenance of fire suppression system.
 Working of High Velocity Water Spray System.
 Working of UHP hose reel.
 Recognizing new types of fire suppression equipment and learn about
their operation.
 Leaned a new rescue technique for rescuing the person from height by
using Bowline On the bite Knot.
 Learned about the hazards involving plant.
 Learned about the working of PTO in detail that actually how shaft gets
changed.
 Refreshed my skill of operation of fire tender.
 Refreshed my skills of operation of fire extinguishers.
It is very good to acquire such a large number of skills in a 33 days training period.
So, training at Heavy Water Plant Baroda can be said to be very valuable.
 Chapter 5: Recommendation

Training is an excellent method and very important to each student in Fire &
Safety engineering, because it teaches us what happens in the field.

The employees of the fire department teach you, from their long time experience,
accept all our questions and encourage you to ask.

The training teaches you the important thing that the engineer must learn: the
regulation and do the work at time.