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) LIMITE
D
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 an
d Hydrogen with Oxygen, resulting in the release of heat energy. Fire is a necess
ary evil. When fire is under human's control, it is a great asset. If human is und
er fire's 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 fi
re fighter can attack a fire in the right manner and, by knowing its weakness, e
xtinguish 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 a
s 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 availa
ble or it will destroy those who seek to restrain it. Fire, when apparently exti
nguished, some untrained person may assume that because the flames have gone, th
e danger is passed, but it may not be so.
Secondly, by considering each fire as an individual occurrence, the correct acti
on in each case will depend on the position of the fire, the combustibles involv
ed and the combustibles, which are in danger of becoming involved. There is no h
ard and fast rule; one who has the knowledge and training can only assert the co
rrect action.
OPERATION AND MAINTENANCE MANUAL Thirdly, by ensuring that properly maintained a
ppliances are available for personnel to use and that all fire fighting, fire de
tection and alarm systems are in fully operational order.
With the rapid growth of the industries and expansion of cities, fire hazards ha
ve also increased. Through considerable attention is being paid by the authoriti
es 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 immed
iate transmission of call on the fire brigade in the event of an out break of fi
re in any premises during the closed hours, and (b) an effective control of a fi
re 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 alar
m 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 th
e 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 maintena
nce of Fire Protection System designed, installed and commissioned by AGNICE FIR
E 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 Vel
ocity 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 regula
tions of Tariff Advisory Committee and National Fire Protection Association. Nee
dless to say, that the efficiency and effectiveness of the system largely depend
s upon proper maintenance of the system and regular training of the personnel op
erating the system. Therefore, the system shall be operated and maintained by tr
ained 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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DRAWING TITLE
P & l Diagram of Fire Hydrant & Spray System Deluge valve arrangement for MVWS a
nd 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 Hydran
t Layout & Isometric for Boilers. Fire Escape Hydrant Layout & Isometric for Con
trol 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 fo
r Boiler Burner Fronts
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OPERATION AND MAINTENANCE MANUAL
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0 PLL-GVK-PEM-127-G-021 PLL-GVK-PEM-127-G-022
DRAWING TITLE
Layout & Isometric of HVW Spray System for Clean and Dirty Oil Tank. Layout & Is
ometric of HVW Spray System for Generator Seal Oil Tank Cooler and pumping unit
Layout & Isometric HVW Spray System for Generator transformer. Layout & Isometri
c of HVW Spray System for Station Transformer. Layout & Isometric of HVW Spray S
ystem 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 Can
al. 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 Syst
em for Coal conveyor BCN-2 Layout & Isometric of MVW Spray System for Coal conve
yor BCN-3 Layout & Isometric of MVW Spray System for Coal conveyor BCN-4A/B Layo
ut & 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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OPERATION AND MAINTENANCE MANUAL
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Layout & Isometric of MVW Spray System for TH-1 transfer tower Layout & Isometri
c of MVW Spray System for TH-2 transfer tower Layout & Isometric of MVW Spray Sy
stem for TH-3 transfer tower Layout & Isometric of MVW Spray System for JNT-1 tr
ansfer tower Layout & Isometric of MVW Spray System for JNT-2 transfer tower Lay
out & 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 contro
l Building. Layout of Fire alarm and detection system for Switch Yard control Ro
om. Layout of Fire alarm and detection system for CHP Control room Layout of Fir
e alarm and detection system for Coal Conveyors 1-4 Layout of Fire alarm and det
ection system for Workshop and ware house. Layout of Fire alarm and detection sy
stem for Air Compressor house. Layout of Fire alarm and detection system for Fue
l oil pump house. Layout of Fire alarm and detection system for service building
.
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7-E-091 PLL-GVK-PEM-127-E-092 PLL-GVK-PEM-127-E-093 PLL-GVK-PEM-127-E-094 PLL-GV
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DRAWING TITLE
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 s
ystem for Admin building. Layout of fire detection and alarm system for fire wat
er pump house Layout of fire detection and alarm system for fire station buildin
g Layout of Fire alarm and detection system for Coal Conveyors 5-10 Layout of Fi
re alarm and detection system for LDO & HFO storage tanks Layout of fire detecti
on 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 wate
r 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 Fi
re water Pumping system. Hydrant System. Automatic Spray system. A. High velocit
y 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 Extinguisher
s. Fire Detection and Alarm System.
4.2 Codes and Standards Proposed Fire Fighting System will be inline with TAC No
rms/NFPA Standards /IS codes. In general the following codes are followed to des
ign the systems. 1. Hydrant System - Fire protection Manual by TAC 2. Spray syst
em - Rules for water spray systems by TAC 3. Foam system - NFPA11 (Standard for
Low, Medium & High expansion Foam) 4. Fire extinguishers - Fire protection Manua
l 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 Pump
ing 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 identic
al 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 sam
e low pressure. The fire pumps starting sequence are automatic based on preset s
ystem 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 u
nder Ordinary Hazard occupancy as per Fire Protection Manual of TAC. The Fire Hydr
ant System for this plant is designed as per the rules applicable to Ordinary Ha
zard Occupancy. The Fire Hydrant System is a wet system and it will be under pre
ssure at all times. The System consists of under ground and above ground pipes w
ith hydrant outlets. Under ground and above ground mains are laid as per approve
d drawings. Pipes are of M.S.ERW pipes and have been coated and wrapped with ant
i corrosive tape & above ground pipes are painted with paints to prevent corrosi
on of pipes. For easy maintenance of underground mains, Isolation Valves have be
en 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 i
s always available for fire fighting service.
Near each yard hydrant point, a hose box has been located to provide 2 Nos. of h
oses and 1 no. of branch pipe. In the event of fire, the hydrant near to the vic
inity 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 se
nsed by pressure switch. As a result, the pumps will start automatically to cate
r 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, veloc
ity 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, e
xtinguishment, and prevention or exposure fire protection. These systems may be
independent of or supplementary to, other forms of protection. These rules are i
ntended to cover water spray protection from fixed nozzles only. The design of s
pecific 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. Wa
ter spray systems are most commonly used to protect processing blocks, processin
g equipments, structures, flammable liquid and gas vessel, piping and equipment
such as transformers, oil switches and some combustible solids, cable trays, cab
le 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 wate
r discharge and distribution over the surface or area to be protected. The pipin
g system is connected to the water supply through an automatically actuated Delu
ge valve which initiates flow of water. Automatic actuation is achieved by opera
tion of automatic detecting equipment installed along with water spray nozzles.
OPERATION AND MAINTENANCE MANUAL A. Automatic HVWS System Automatic H.V.W.S Syst
em is provided for Transformers, Lube oil tanks & cooler, Boiler feed water pump
s cooler, Boiler Burner front. Detection system shall be of quartzoid bulbs and
both detection and protection lines shall be supervised using pressure switch. D
eluge valve can be opened either hydraulically by the pilot head detectors or ma
nually. The system shall be actuated in any one of the following ways during a f
ire condition. 1. In case of fire, the Quartzoid bulb shall break thereby releas
ing the pressure in the detector network. This shall hydraulically open the delu
ge 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 s
tation is also provided in addition to the above. B. Automatic MVWS System Autom
atic 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 smo
ke detectors and LHS cables for fire detection. The fire protection line is supe
rvised using a pressure switch. The deluge valve can be - opened electrically us
ing solenoid automatically. Manual actuation by releasing the emergency release
station is also provided. Coal Conveyor Galleries / Conveyor Tunnels: 1. Coal co
nveyor 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. Sp
ray system shall cover both forward and return belts. 3. On detection of fire, t
he 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 h
ead end and one located near the mid way between the head and tail and third nea
r 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 co
nnector 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 wi
th 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 Cabl
e galleries/ Cable vaults shall consist photoelectric type smoke detectors. 4. A
single run of LHS cable shall also provided running along top, bottom and alter
nate length of intermediate cable trays. Transfer points in CHP Area: 1. Transfe
r point Spray system is designed with a density of 10.2 lpm/Sq.m 2. Transfer poi
nts at various levels are provided with spray System. 3. Fire detection system f
or Cable vaults shall Digital LHS Cables.
OPERATION AND MAINTENANCE MANUAL 4.1.4. Manual MVWS System A. LDO/HFO Storage ta
nk: Manual M.V.W.S System is provided for LDO Storage tanks. Manual activated sp
ray system is provided to cool down the tank wall and roof against excessive hea
t and isolate it from other nearby tanks under fire situation with a water appli
cation 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 t
he 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 sys
tems and their components shall be designed as per NFPA recommendations. 3. Foam
protection system for each tank shall have one riser with foam chamber assembli
es 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 op
eration. Oil tanks shall be provided with ROR type heat detectors inside the tan
k roof for automatic actuation of the foam system and initiating alarm to the lo
cal panel as well as main fire panel located in TG Building. Water supply for fo
am system shall be tapped from the nearest hydrant header.
OPERATION AND MAINTENANCE MANUAL 4.1.6 Portable Fire Extinguisher: In general th
e extinguishers shall be provided based on the rules specified in TAC hydrant ma
nual.
Sl. No. Type 01 02 03 04 CO2 Fire Extinguishers Dry chemical type Extinguisher F
oam 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 Manu
al call points located at various places are connected to the Fire Alarm Panel b
y 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 w
hich in turn actuate an Audio/visual alarm in the panel, and the external hooter
s 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 maintain
ing the complete system in satisfactory operation for at least 24 hours in the e
vent of AC supply failure. Manual call points shall be located at strategic loca
tions 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 frang
ible top cover. The detectors to be used in FDA system:1. Smoke detectors, confo
rming to IS : 11360 2. Heat detectors, both fixed type and rate of rise type, co
nforming to IS: 2175 3. Infra red ember detectors 4. Three runs of LHS cable sha
ll be provided running all along the conveyor to cover top, bottom belt and roll
er 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 Cap
acity 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 maintain
s 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. Wh
en the water level in the Hydro Pneumatic tank falls due to minor system leakage
s, the jockey pump will start and fill the tank. Level switches installed on Hyd
ro-pneumatic tank control Starting/stopping of Jockey Pump. The low-level condit
ion starts jockey pump. When desired water level is reached, the jockey pump sto
ps. During initial filling of the Hydro-pneumatic tank, the Jockey Pump (main) w
ill 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 K
g/cm2(g).During normal working condition, when water level falls in the Hydro-pn
eumatic 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 pum
p (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 compres
sors are provided to compensate the minor air leakages. Due to minor air leakage
s, 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 pu
mp 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 con
trolled through the pressure switches fitted in the hydrant and spray system hea
ders. Starting and stopping of jockey pumps are controlled through level switche
s fitted in the hydro-pneumatic tank. 5.2.1. HYDRANT SYSTEM When any of the hydr
ant 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 p
ump shall not be sufficient to meet the large requirement. As a result, the pres
sure in the hydrant line will fall further and impulse from pressure switch in t
he 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 pressu
re 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, Dies
el Engine driven main pump (HPP-3) will come into operation when the demand is e
ven more at 6.5 Kg/cm2(g). In addition to the above pumps, a Diesel Engine drive
n stand-by pump (HPP-4) is also provided to cater the water requirement incase o
f failure of all or one of the main pumps at 5.5 Kg/cm2(g).Thus, an automatic se
quential starting of pumps will be proved with a status indication in the contro
l panel. Pumps can be started manually in case of emergency. However pumps can b
e 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 w
ater at the desired pressure of 10.5 Kg / cm2(g). On detection of fire, the auto
matic actuation of deluge valve decreases pressure in spray pipeline. Capacity o
f the hydro-pneumatic tank and jockey pump shall not be sufficient to meet the l
arge 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 pressu
re or if the header pressure still falls when spray pump is running then the sig
nal 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 dies
el engine driven pump to start, the header pressure will fall further and sequen
tially, the header non-return valve will allow water from hydrant header to spra
y header. This will decrease the pressure in hydrant header resulting in startin
g of hydrant pumps as explained in 4.2.1 to cater the spray system. As because o
f 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 pre
ssing 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 brea
k 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 wit
h nozzle to one end of hose having female coupling. Connect the other end of hos
e with male coupling to the hydrant valve. Hold the hosepipe with branch pipe an
d 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 t
he monitor nozzle. Adjust the jet towards the fire vertically and lock it. Relea
se 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 grad
ually. After the valve is opened, if the water is not playing on the seat of fir
e, 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 explain
ed 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 s
ystem, the rapid rise in temperature will cause the liquid inside the fragile gl
ass 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 t
he 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 networ
k 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 flow
ing through the spray network and projectors will spray the water to the Transfo
rmer. 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 fir
e is detected, open the deluge valve by one of the following methods manually. O
pen the emergency release release valve near the deluge valve.
OPERATION AND MAINTENANCE MANUAL 5.5 Foam System Incase of fire, in LDO or HFO s
torage 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 t
he 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 t
he foam concentrate to form a foam solution, which will further travel to foam c
hamber. Foam chamber has got an inbuilt foam maker which will produce foam and d
ump 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 fi
re 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 t
ypes of Fire Detectors located at the various locations are connected to the Fir
e 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 Manu
al Call Point's "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 sys
tem for normal operation, "BREAK GLASS of the Manual Call Point has to be replace
d and the panel has to be reset through Reset Push Button.Purpose of this manual c
all points is to inform the panel about the fire condition when the fire is dete
cted manually. Just by pressing the manual call point, the signal can be transfe
rred to the panel. All the other operations of the panel shall be same as of aut
omatic operation.When the manual call point is pressed the panel display unit wi
ll display the exact location of manual call point, so that the operator can ide
ntify 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 undergr
ound 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 a
ttains 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 t
he 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 p
umps in `Auto' mode.
OPERATION AND MAINTENANCE MANUAL 6.2.2 M.V.W.S. System: A. Keep all the isolatio
n 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 a
ll the isolation valves (Upstream & down stream of Deluge Valve Assembly) closed
. So that the system pressure will be restored. E. Open the upstream and downstr
eam line isolation valves. F. Stop the pump manually when the pressure in the sy
stem attains 8.8kg/cm2. G. Keep all the pumps starting in `Auto' mode. H. Keep all t
he pumps in `Auto' mode. 6.3 Foam System A. Keep all the isolation valves in open co
ndition, except the by-pass valve. B. Activate the solenoid valve of deluge valv
e. 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 Assem
bly) 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 pressur
e 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 inst
allation shall be tested to ensure that it operates satisfactorily & that, A. Al
l Detectors and Manual Call Points function correctly. B. All ancillary equipmen
t's functions correctly.
6.4.1 Smoke Detectors / Heat Detectors:
1.
Create a Smoke / Heat by using any reliable source near to the smoke / Heat Dete
ctor.
2. 3. 4. 5. 6.
After sometime, observe the alarm in the corresponding panel The fire signal wil
l be transferred to Fire Alarm Control Panel. Observe the Area name of the respe
cted area of fire. Observe the sound of the corresponding Hooter. By pressing `Ala
rm 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 Norm
al 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 A
rea name of the respected area of fire. Observe the sound of the corresponding H
ooter. By pressing Alarm Silence Push button in the panel, the respected area hoot
er will be silenced. After completion of testing, press, Reset Push Button to rest
ore 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 esse
ntial 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 maintai
n 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 diffe
rent 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) we
t 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 sy
stem 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 oper
ation. Actuating the manual pull switch will operate the spray system. During th
e spray discharge, it should be checked. i) Whether the alarm is working. ii) Wh
ether 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 in
spected.
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 labo
ratory for quality condition testing. C. Quantity of concentrate in storage shal
l meet design requirements, and tanks or containers shall normally be kept full,
with space allowed for expansion. 7.4 Extinguishers 1. Examine Extinguisher bod
y 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 detect
or shall be checked visually by seeing the LED glowing. 2. Every week the batter
y should be checked for the charge availability. 3. Daily, Panel display shall b
e checked for any event happenings. If there is any fault the same should be att
ended 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 maintenanc
e work, notify the authorities that the system is undergoing maintenance. All pe
rsons who might receive an alarm signal should be notified in advance to avoid u
nnecessary 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 i
nspected externally Cleaning of Hose boxes/ Hose stations internally & externall
y Polishing of hose couplings / branch pipes Washing of hose pipes in clean wate
r & 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 part
s Clean superficially Weigh gas cartridges, if there loss of more than 10% of or
iginal mass, send it for clogging Grease the cap threads and plunger Check the v
ent holes for clogging Check the sealing washer & replace if necessary Operation
test- half the number of water type Extinguishers Operation test- half the numb
er of dry powder Extinguishers Examine the inside surface of the cylinder for co
ndition of plating, rusting. Monthly Monthly Monthly Monthly Monthly Monthly Mon
thly 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 exting
uishers 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 typ
e Dry chemical type Foam type Test interval 3 Years 3 Years 3 Years Test pressur
e 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) p
ower 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 mon
ths 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 circ
uits and short circuits, and power supply supervision for detection of loss of A
C power and disconnection of secondary batteries Fuses Remove fuse and verify fo
r accurate rating. Operate `Lamp test' switch and verify whether lamps / Lamps and L
EDs LEDs illuminates. Secondary (standby) power supply shall be disconnected Pri
mary (main) Power and tested under maximum load, including of all alarm supply a
ppliances 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 gener
al alarm systems for a minimum of 5 min. Reconnect primary power supply at the e
nd of test.
a)
b) c) d)
e)
OPERATION AND MAINTENANCE MANUAL
9. TECHNICAL DATASHEETS
OPERATION AND MAINTENANCE MANUAL 9. DATASHEETS 9.1 DATASHEETS 1. Main Pump (moto
r & 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.W
ater 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 cont
rol panel 20. Smoke detectors 21. Heat detectors 22. Probe type Heat detectors 2
3. Infra red detectors 24. Linear Heat Sensing Cable 25. Control Cables 26. Exti
nguishers 27. Foam System Components