Fire Detection & Protection System

TATA CONSULTING ENGINEERS LIMITED
TCE.6769A-ME-608CN-03
CONCEPT NOTE ON
FIRE DETECTION & PROTECTION SYSTEM
SECTION:
TITLE SHEET
SHEET i OF ii
OF 4
MURUGAPPA GROUP
PROPOSED GREEN FIELD PROJECT FOR

M/s TUBE INVESTMENTS INDIA LTD.,
AT PONPADI VILLAGE, THIRUTHANI, THIRUVALLUR
DISTRICT, TAMIL NADU
CONCEPT NOTE ON
(DOCUMENT NO. TCE.6769A-ME-608-CN-03)
TATA CONSULTING ENGINEERS LTD.

6th Floor, SKCL Central Square-I,
No.C-35, CIPET Road, Thiru-vi-Ka Industrial Estate,
Guindy, Chennai 600 032.
JANUARY 2013
FILE NAME: TCE.6769A-ME-608-CN-03
P0
04.01.2013
RVK
MSN
REV.
NO.
DATE
PREPARED
BY
CHECKED
BY
VAK
CLEARED BY
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BY
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TCE.6769A-ME-608CN-03
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CONTENTS
SHEET ii OF ii
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CONTENTS
1.0 INTRODUCTION................................................................................................1
2.0 SCOPE............................................................................................................... 1
3.0 DESIGN OBJECTIVES.......................................................................................2
4.0 FUNCTION......................................................................................................... 2
5.0 INPUT DATA.......................................................................................................3
6.0 SYSTEM DESIGN..............................................................................................4
7.0 SYSTEM DESCRIPTION AND DESIGN REQUIREMENT................................10
8.0 FIRE DETECTION & ALARM SYSTEM............................................................16
9.0 INSTRUMENTATION AND CONTROL (I&C) SYSTEM REQUIREMENT..........22
9.0 FIRE EXIT & ASSEMBLY POINT.......................................................................23
10.0 CODES & STANDARDS..................................................................................24
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1.0 INTRODUCTION
Tube Investments proposes to put up Chain & Tube Manufacturing Plant at Ponpadi
Village near Thiruthani, Thiruvallur Dt.,Tamil Nadu. The plant consists of separate
tube manufacturing unit & chain manufacturing unit. This concept note describes the
fire protection system for both the units.
2.0 SCOPE
This concept note briefly describes various types of fire protection systems provided
for the plant.
The total fire protection system is categorised into the following types:
A) Hydrant System
-
Entire Chain & Tube manufacturing plant area.
B) High Velocity Water Spray System (HVWS):

- 15 MVA Transformer in Switchyard in Tube unit
C) Medium Velocity Water Spray System (MVWS):
- 14.4 MT LPG Bullet (3 nos. of 4.8MT each) in Tube Unit
D) Sprinkler System for the following buildings:
Chain Unit
- Office / Stores / Maintenance
- Product Testing & Development / Admin Office
- Canteen / Rest Room / Lockers
Tube Unit
- Admin / Training Hall
- Canteen
E) Fire Extinguishers & Signages for the all the plant & non-plant buildings in tube &
chain unit.
F) Fire Alarm & Detection System
- Entire Chain & Tube manufacturing plant area.
It outlines the input data and assumptions, system description, equipment
description, control and operation philosophy, electrical requirement, instrumentation
requirement, safety feature, design Codes and standard references.
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3.0 DESIGN OBJECTIVES

The objective of this concept note is to:
(a)
Recommend optimum fire protection / fighting systems for various facilities as

per statutory requirement.
(b)
Present major parameters and brief description of each type of fire fighting
systems/equipment proposed.
4.0 FUNCTION
The hydrant system which is provided throughout the plant shall be operated to
control & extinguish fires in incipient or advanced stages.
HVWS is provided to extinguish & control fire in 15mva transformer located in
switchyard in tube unit. Fire control and protection system will trip the transformer
on an event of fire detection from the transformer zone before the system starts
extinguishing the fire. Detection line is provided, which will open the deluge valve
and extinguish the fire through the protection line.
MVWS is provided to extinguish & control fire in LPG bullet in tube unit The
function is similar to HVWS.
Sprinkler System is provided to detect & extinguish fire in non-plant buildings. A
sprinkler will perform two functions, it will first detect a fire, and then provide an
adequate distribution of water to control or extinguish it.
The portable fire extinguisher which shall be located all over the premises are used
for extinguishing incipient fires. Signages are provided for emergency evacuation and
identification of fire protection accessories.
The objective of using specific detectors of FDAS system is to detect the presence of
smoke / fire in incipient stage or early stage and initiate an audible and visible
annunciation at predetermined locations to alert the building occupants about fire. The
word incipient means a stage of fire which provides invisible smoke, no heat and no
visible flame generated. Also, the information about the fire has to be transmitted to
security personnel for the fire fighting purpose. In the design, the maximum allowable
response delay from activation of an initiating device to receipt and display by the Fire
Alarm Control Panel (FACP) is within 10 seconds.
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5.0 INPUT DATA

5.1
As per clause 7.2.1 in Fire Protection Manual of Tariff Advisory Committee (TAC) 12th
edition, 1998 Engineering Workshop is classified under Light Hazard risk. This
plant is considered as Engineering Workshop. However due to the presence of LPG
bullets and other combustibles the requirements of Ordinary Hazard risk is
considered for design of reservoir. It is envisaged to have a separate storage tank &
pump house for chain & tube unit.
The areas where various fire protection systems are to be provided are listed below.
Fire hydrant system and Portable extinguishers: Provided throughout the premises,
the main buildings / areas of which are as under:
S. No.
Area
Chain Unit
Parking areas, Security
Product Testing & Development / Admin Office
Assembly Shop
Heat Treatment Shop
LPG/Ammonia Manifold
Parts Production Shop
Maintenance / Central Tool Room & Office
Scrap Yard
Maintenance Office / Stores
10
M/C Service / Repair
11
Fabrication Area
12
Mechanical / Plumbing Contract
13
HSD & Methanol Underground Storage
14
ETP/STP/RO
15
Pump House
16
Parking Areas
17
Canteen /Rest Room / Lockers
18
Electrical Substation
19
DG Yard
Tube Unit
20
Parking areas, Security,
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S. No.
Area
21
Admin / Training Hall
22
TPI Plant
23
Switchyard, Transmission Corridor, Substation
24
HSD Storage Area
25
Diesel Generator House
26
Canteen / Gym / Rest Room
27
LPG Bullet
28
ETP & STP
29
Stores, Comp Room, Tool Room
5.2
As per TAC guidelines, it is decided to run common 200 / 150 mm dia underground
mains for hydrant, spray and sprinkler system with a common pumping arrangement.
5.3
As per TAC guidelines, it is also decided to have delivery pressure of fire pumps as
70 metre water column. (mWC).
6.0 SYSTEM DESIGN

6.1
Water based fire protection systems

Common pumping and pipe mains have been considered for the water based
systems hydrant, spray & sprinkler system. The term `hydrant mains shall mean
the common mains for hydrant, spray & sprinkler systems.
6.2
TUBE UNIT
6.2.1
Hydrant System
The distance maintained between each hydrant around the building to be protected is
30 mtr as per the requirements of Fire safety Installations & Life Safety Measures for
various types of occupancies issued by Tamil Nadu Fire & Rescue Services
Department.
Hence approx. 58 nos. of external hydrants and 10 nos. of internal hydrants are
proposed for the entire plant including future expansion. Also 4 nos. water monitors
are proposed in underground HSD & Methanol storage area.
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Therefore, the hydrant system consists of:

Qty
Equivalent Hydrants
as per TAC
Hydrant Valve (External)
57
57
Hydrant Valve (Internal)
10
10
Water Monitor
04
12
Item
Total Hydrants Points as per TAC

6.2.2
79
High Velocity Water Spray System

HVWS is provided for the transformers located in the switchyard as listed in clause
2.0 above.
Transformer dimension including radiator &

condenser (Approx.)
Dimension in mtr (LxBxH)
Total Surface area of transformer in m
2(LxB+BxH+HxL))
Design density for spray system
(as per Cl. 3.2.3.6.1 in TAC rules for Spray System)
Flow required in lpm
Hose stream demand in lpm
(as per Cl. 7.4.1.4.6 in TAC FP manual)
Total flow required in lpm with 10% Margin
Total flow required in m/hr
7.5x6.7x5.0
242.5
10.2 lpm/m
2473.5
1750
4471
269
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Medium Velocity Water Spray System

MVWS is provided for the LPG bullets as listed in clause 2.0 above.
Bullet dimension (Approx.)

Dimension in mtr (LxDia)
7.7x1.5
Surface area of bullet in m
39.82
Design density for spray system

(as per Cl. 4.5.3.1 in TAC rules for Spray System)
10.2 lpm/m
Flow required in lpm for one LPG mounded bullet
406.21
Total flow required in lpm for three LPG bullets
1219
Supplementary Hose stream demand in lpm

(as per Cl. 7.4.1.4.6 in TAC FP manual)
1750
Total flow required in lpm with 10% Margin
3091
Total flow required for one tank in m/hr
185
6.2.4 Fire water Pumps Capacity & Head selection

As per requirements of TAC (Refer Table 2, SL. No. 2 of TAC - Fire Protection
Manual), for ordinary hazard & number of hydrants not exceeding 100, 1 no. pump of
capacity 273 m3/hr and 70 mWC head shall be provided.
Hence 273 cum/hr pump is proposed for the water based fire protection system of
TPI, which shall also meet the flow requirement of HVWS & MVWS systems.
Maximum height the hydrant main has to supply water in the building is 19 meters,
and 200 / 150 mm dia size mains have been envisaged, hence it would be sufficient
to have the head of the pumps as 70 mWC.
6.2.5
Water storage as per TAC rule shall be:

As per TAC, not less than 2 hours of aggregate pumping capacity is to be provided
as storage for fire fighting system as per TAC guidelines.
That is, 2 hrs. x hydrant pumping capacity = 2 x 273 = 546 m3
Hence total capacity proposed for exclusive use for fire protection = 546 m3
Reservoir capacity to be provided for fire protection = 550 m3
It has been proposed to have a separate RCC aboveground reservoir for fire water
purposes. It is also proposed to construct fire water pump house in such a way to
take advantage of positive suction. The total capacity required for fire fighting shall be
in two interconnected compartments connected by a common header to facilitate
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periodic cleaning. The capacity of fire water tank is 550 cum considering 2 hrs
aggregate pumping capacity of fire pump.
6.2.6
Jockey Pump capacity

As per TAC rule, when the pumping capacity is less than 820 m3/hour, the required
capacity of jockey pump shall neither be more than 5% of the installed pumping
capacity nor less than 3% thereof (with a minimum of 10.8 M3/hr).
Hence, jockey pump of capacity 10.8 m3/hour shall be provided. The head of the
jockey pump shall be equal to that of main pumps, i.e. 70 mwc.
It is recommended (not mandatory) to provide alternative power source from
emergency Diesel Generator set for main motor driven and Jockey Fire water pumps.
List of Equipments:
Sl.
No.
(i)
(ii)
(iii)
Name
Electric Motor driven
Main Fire Pump
Diesel Engine driven
Standby Fire Pump
Jockey Pump
6.3
CHAIN UNIT
6.3.1
Hydrant System
Quantity
Parameter
01
273 m3/hr. @ 70 mWC total head
01
273 m3/hr. @ 70mWC total head
01
10.8 m3/hr. @ 70 mWC total head
Pressurised fire hydrant system is provided for the entire plant.

The distance maintained between each hydrant around the building to be protected is
30 mtr as per the requirements of Fire safety Installations & Life Safety Measures for
various types of occupancies issued by Tamil Nadu Fire & Rescue Services
Department.
Hence approx. 38 nos. of external hydrants and 8 nos. of internal hydrants are
proposed for the entire plant including future expansion. Also 3 nos. water monitors
are proposed in underground HSD & Methanol storage area.
Therefore, the hydrant system consists of:
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Qty
Equivalent Hydrants
as per TAC
Hydrant Valve (External)
38
38
Hydrant Valve (Internal)
08
08
Water Monitor
03
03
Item
Total Hydrants Points as per TAC
49
6.3.2 Fire water Pumps Capacity & Head selection

As per requirements of TAC (Refer Table 2, SL. No. 2 of TAC - Fire Protection
Manual), for light hazard & number of hydrants not exceeding 100, 1 no. pump of
capacity 171 m3/hr and 70 mWC head shall be provided. Totally 31 hydrants can be
added in the hydrant network during future expansion of TIDC.
Hence 171 cum/hr pump is proposed for the water based fire protection system of
TIDC.
Maximum height the hydrant main has to supply water in the building is 14 meters,
and 200 / 150 mm dia size mains have been envisaged, hence it would be sufficient
to have the head of the pumps as 70 mWC.
6.3.3
Water storage as per TAC rule shall be:

Since it is envisaged to have a separate storage tank & pump house for chain unit in
addition to the tank and pump provided in the tube unit, it is decided to provide tank
of capacity not less than 1 hours of aggregate pumping capacity. Seperate
interlinking of the hydrant system of the two units are provided.
That is, 1 hr. x hydrant pumping capacity = 1 x 171 = 171 m3
Hence total capacity proposed for exclusive use for fire protection = 171 m3
Reservoir capacity to be provided for fire protection = 175 m3
It is envisaged to have a common storage tank for raw & fire water requirements.
It has been proposed to have RCC belowground reservoir for fire and raw water
purpose. It is also proposed to construct fire/raw water pump house above the below
ground reservoir and provide vertical turbine/submersible pumps. The total capacity
of the tank shall be in two interconnected compartments connected by a common
sump to facilitate periodic cleaning. The capacity of fire and raw water tank is 700
cum considering 1 hr aggregate pumping capacity of fire pump i.e., 175 m 3 and 3
days storage of the entire plant requirement.
6.3.4
Jockey Pump capacity
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As per TAC rule, when the pumping capacity is less than 820 m3/hour, the required
capacity of jockey pump shall neither be more than 5% of the installed pumping
capacity nor less than 3% thereof (with a minimum of 10.8 M3/hr).
Hence, jockey pump of capacity 10.8 m3/hour shall be provided. The head of the
jockey pump shall be equal to that of main pumps, i.e. 70 mwc.
It is recommended (not mandatory) to provide alternative power source from
emergency Diesel Generator set for main motor driven and Jockey Fire water pumps.
List of Equipments:
Sl.
No.
(i)
(ii)
(iii)
6.4
Name
Main Fire Pump
Diesel Engine driven
Standby Fire Pump
Jockey Pump
Quantity
Parameter
01
171m3/hr. @ 70 mWC total head
01
171 m3/hr. @ 70mWC total head
01
10.8 m3/hr. @ 70 mWC total head
Portable Fire Extinguishers

Following Portable Extinguishers are proposed as per TAC guidelines:
Sr. No.
Type of Extinguisher
(a)
Carbon dioxide (CO2) type as per IS: 2878 @ 4.5 kg capacity.
(b)
ABC type as per IS: 13849 @ 1.0 / 2.0 / 4.0 kg capacity
(c)
Mechanical Foam type as per IS: 10204 @ 9 ltr / 50 ltr

capacity. AFFF type foam shall be provided inside the
extinguisher.
7.0 SYSTEM DESCRIPTION AND DESIGN REQUIREMENT (ADDITIONAL DETAILS)

7.1
Pumping system:
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a.
The jockey pump shall be used for make-up of leakages. The start-stop of
jockey pump and start of motor and engine driven pump shall be automatic by
individual pressure switches.
b.
Stopping of fire water pumps shall be manual. Additionally a pressure switch

shall be provided on header for sensing header pressure low. A pressure
gauge shall be provided at discharge of each pump.
c.
Each pump shall be assigned a dedicated pressure switch in the common

delivery header for automatic operation in the following sequence:
Sr. No.
Description
Set Pressure
(in kg/cm2)
Main Jockey pump starts
6.0(g)
Jockey pump stops
7.0(g)
In the event of Fire (Hydrant system):

3
Main pump starts
5.5 (g)
Standby pump starts
4.5 (g)
However, the pressure setting of starting the pumps will be finalised in the
detail engineering phase. Also, the pressure switches shall have flexible range
to select a particular pressure.
d.
Motor-Control Centre and Local Control panel shall be located in the fire
water pump house. A repeater annunciation panel shall be located in security
office.
e.
As flooded suction is available in tube unit, the pumps shall be horizontal

centrifugal type and as flooded suction is not available in chain unit, the
pumps shall be vertical turbine type. Further it is proposed that both electric
motor driven and diesel engine driven pumps shall be completely interchangeable including direction of rotation, so that maintenance is easier.
f.
The fire water pump characteristics shall be as per TAC guidelines. Pumps
shall be capable of furnishing not less than 150% of rated capacity at a head
of not less than 65% of the rated head. The shut-off head shall not exceed
120% of rated head for horizontal pumps and 140% of rated head for vertical
pumps.
g.
Motor shall be squirrel cage operating on 415 V, 3 supply and TEFC. Supply
conditions for which motors are desired to operate are 10%, 3%, 10%
respectively for voltage, frequency and combined voltage and frequency.
Motors shall be of S1 duty and DOL starting. The class of insulation shall be
'F'. Motor shall be IP 55 protected.
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Diesel engine shall be heat-exchanger cooled, battery started and

"continuous" duty type. Diesel engine shall be capable of running on HSD
fuel. The engine shall conform to requirements of TAC Fire Protection
manual.
A stand / wall mounted panel having start-stop facilities and following
indications/annunciation shall be provided:
i.
ii.
iii.
iv.
v.
vi.
vii.
viii.
7.2
Speed indicator
Indication for state of battery charge
Low level alarm of fuel in day oil tank
Engine over speed alarm
High jacket water temperature alarm
High lube oil temperature alarm
Jacket water outlet temperature
Lube oil pressure
Hydrant System
(a)
The proposed hydrant system mainly consists of pumps, piping, external and
internal hydrant valves, water monitor, isolation valves and hydrant
accessories.
(b)
The hydrant system mains shall be 200 / 150 mm dia. It shall be validated by
hydraulic calculations that a residual pressure of at least 3.5 kg/cm (g) is
available at the hydraulically farthest hydrant outlet.
(c)
Orifice plate is fitted to hydrant outlets to limit the residual pressure to within
4.5 kg/cm2 (g) to enable the operator to hold the branch pipe and nozzle
without being subjected to excessive reaction thrust.
(d)
The external hydrants shall be provided for every 30 meters of external wall
measurement as per Tamil Nadu Fire & Rescue Services Department. One
hose cabinet, consisting of two nos. 15 m long hoses with couplings, one
branch pipe with nozzle, is suitably mounted on the wall or over ground near
each external & internal hydrant. Each riser pipe feeding the internal hydrants
is provided with drain, vents and isolation valve at ground level.
(e)
The fire water piping shall run aboveground in pedestals at an elevation of

minimum 300 mm aboveground (bottom of pipe) in the form of ring main.
Carbon steel pipes shall be used for above ground fire water piping & road
crossings in hume pipe.
The Cast steel pipes shall be joined using butt welding by shielded metal arc
welding. Pipe edges to be butt welded shall be bevelled by using grinding
machine only. The cast iron pipes shall be joined by socket & spigot
arrangement.
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(f)
The fire water piping shall run through underground hume pipe (NP3) at all
road crossings and to avoid interference with other services.
(g)
Wrapping & Coating shall be applied on the underground portion of pipes as

anti-corrosive treatment.
(h)
The fire water piping layout is designed to supply water from two or more
routes to each area. Adequate numbers of isolation valves are provided to
ensure that when a particular section of pipeline is to be isolated for
maintenance work, the rest of the system remains in working condition all the
time. All the branch connections taking off from ring mains and entering
building are provided with isolation valves outside the building.
(i)
All isolating valves in the system are kept in LOCKED OPEN' condition.
(j)
Brief specifications of major components are proposed as follows:

(i)
Pipes up to and including 200mm NB shall conform to IS:1239

(Medium) and pipes of 200mm NB and above shall conform to
IS:3589 (min. wall thickness of 4.85mm for sizes less than or equal to
350mm and 6mm for higher sizes)
(ii)
Isolating valves in suction side of pumps shall be cast iron rising

stem gate valves conforming to IS: 14846. All other isolating valves
shall be wafer pattern butterfly valves of cast iron construction.
(iii)
Hydrant valves shall be 63mm Gun-metal ISI marked oblique pattern

conforming to IS: 5290 Type A.
(iv)
Branch pipes with nozzle shall be 63mm Gun-metal ISI marked short
pattern (other than fog nozzles) conforming to IS: 903.
(v)
Hose pipes shall be 63mm Reinforced Rubber-lined with gun-metal

instantaneous couplings duly bound at either end and conforming to
IS: 636 Type A.
High Velocity Water System

The proposed HVWS system is a tap-off from the hydrant ring main and it mainly
consists of detection and protection piping, quartzoid bulb detectors, spray nozzles,
deluge valve, Y type strainer and isolation valve.
(a)
Automatic HVWS system mainly consists of two networks are as follows:

i)
ii)
(b)
Fire detection & actuation network

Fire quenching network
Fire detection & actuation network consists of pressurised piping with

Quartzoid bulb Detectors (QBD) placed around the transformer to be
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protected, with instruments, controls, structural/masonry supports as per

relevant codes, standards and regulations.
(c)
Fire quenching network consists of spray piping with open spray nozzle
around the equipment to be protected, with deluge valve (DV), isolation
valves, strainer, instruments, controls, cabling and other related accessories
with necessary fittings, flanges, gaskets, fasteners & consumables, their
grouting, structural/ masonry supports as per relevant codes, standards and
regulations.
(d)
Design density for the HVWS system is considered to be 10.2 lpm/m as per
TAC guidelines. The system functions as mentioned below:
(e)
The heat sensing QBDs (liquid filled glass bulb type) are mounted on the
pressurised water piping network around the equipment. The fixed
temperature rating of the detectors is 79C. Under fire conditions, one or
more bulbs break causing the water to escape from the charged detection
pipe work, thus relieving the pressure. Fire quenching network is closed by
the deluge valve (DV), so the water pressure in the fire detection & actuation
network is maintained. Once the water pressure in the fire detection &
actuation network falls below a set pressure by the breakage of QBD at the
outbreak of fire, the DV in the fire quenching network opens, and the high
velocity water spray achieved through the spray nozzles is directed to the
equipment. At a preset low pressure value the DV opens allowing water.
(f)
The spray nozzles used in the spray system have a bore size of 6 mm to 10
mm range. Therefore suitable strainer of 2 mm opening is required upstream
of deluge valve to prevent clogging of spray nozzles. Strainer is fitted
between branch line isolating valve and deluge valve. This also facilitates
periodic testing/cleaning of strainer. The nozzles are provided with blow off
caps to prevent dirt accumulation in the nozzle. The nozzle should be made
of corrosion resistant material namely nickel plated brass or bronze.
(g)
By-pass line with isolation valve is also proposed to keep the water availability
at all times in case of deluge valve failure.
(h)
The above ground pipes beyond deluge valve are normally dry and subjected
to atmospheric conditions. Therefore the pipes considered are carbon steel
galvanised, heavy class to provide protection against atmospheric corrosion.
(i)
Projectors on the rings shall be located at not less than 500 mm and not more
than 800 mm from the transformer surface. Spacing of detectors on rows
shall not exceed 2.5 m. The spray nozzles shall be located at a distance not
more than 3m on water spray distribution pipe.
(j)
The size of detection piping should not be less than 25 mm diameter

anywhere.
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(k)
The DV for equipment at grade level shall be located at 6m to 15m distance

away from hazard to enable manual operation during emergency. Discharge
outlets of the DVs shall be routed from grade level to the areas it is protecting
through risers. The spray risers shall be provided with isolation valves on
upstream side of DVs in LOCKED OPEN position.
(l)
The protection piping network shall be hydraulically so designed as to provide

a minimum running pressure of 3.5 bar at the hydraulically most un-favorable
sprayer and not more than 5.0 bar at the hydraulically most favorable sprayer
in the network.
(k)

(i)
Pipes up to and including 150mm NB shall conform to IS: 1239

(Medium) Galvanised.
(ii)
Deluge valves shall be 80/100/150 mm Cast Iron & UL/FM listed with
water motor gong and wet pilot trim.
(iii)
Spray Nozzles with brass body & nickel plated finish. Open headed
type and UL/FM listed.
(iv)
Quartzoid Bulb Detectors with brass body & nickel plated finish.
Pendent type and UL/FM listed.
Medium Velocity Water System

(a)
The proposed MVWS system is a tap-off from the hydrant ring main and it
mainly consists of detection and protection piping, quartzoid bulb detectors,
spray nozzles, deluge valve, Y type strainer and isolation valve.
(b)
Automatic MVWS system is similar to automatic HVWS system in operation

except that instead of HVWS nozzles, MVWS nozzles are used in this
system.
(c)
Design density for the MVWS system is considered to be 10.2 lpm/m as per
TAC guidelines.
(d)
The protection piping network shall be hydraulically so designed as to provide

a minimum running pressure of 1.4 bar at the hydraulically most un-favorable
sprayer and not more than 2.4 bar at the hydraulically most favorable sprayer
in the network.
Sprinkler System
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(a)
Sprinkler system is provided for the areas as listed in Clause 2.0 above.
(b)
Automatic sprinkler system consists of a water supply and one or more

sprinkler installations; each installation consists of a set of installation control
valves and a pipe array fitted with sprinkler heads.
(c)
In case of fire at specific location, sprinkler bulb (Q.B.) in the vicinity of that
area shall break at predetermined temperature on heating and discharge
water avoiding fire damages to other non-fire portion of the areas and
equipment in the building.
(d)
Automatic sprinkler system shall be designed and installed in accordance with

TAC/ IS: 15105.
(e)

(i)
Pipes up to and including 150mm NB shall conform to IS: 1239

(Medium) Galvanised.
(ii)
Alarm valves shall be 150 mm Cast Iron & UL/FM listed with water
motor gong assembly.
(iii)
Quartzoid Bulb Detectors with brass body & nickel plated finish.
Pendent type and UL/FM listed.
(iv)
Sprinkles Standard Response Upright / Pendent type
Fire Extinguisher
a) The nature of Combustibles viz. paper, wood, oil, cable, etc present within the
protected areas determines the class of fire expected in that area. The
description of various classes of fire as defined by IS: 2190 are given below:
(i)
Class A Fire
Fire in ordinary solid Combustibles

woods, paper, plastics, rubber, etc.
(ii)
Class B Fire
Fire due to inflammable liquids - oil, paint,

solvent, etc.
(iii)
Class C Fire
Fire in energised electrical equipment,

motors, switchgear, transformers etc.
(iv)
Class D Fire
Fire in reactive chemicals and active

metalsmagnesium, sodium, plutonium
etc
b) Some types of extinguishers are suitable for more than one class of fire. The
different types of extinguishers and their suitability to extinguish various classes
of fire are given below:
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Type of Extinguisher
Suitable for Class of Fire
Mechanical Foam Type
ABC/ Dry Chemical Powder (DCP)

Type
A, B, C, D
CO2 Type
B, C
c) The extinguisher location is decided based on following considerations:

i.
ii.
iii.
iv.
v.
Travel distance of 15 metres maximum

Uniform distribution,
Easy accessibility,
Nearness to doors, windows, emergency doors and escape
routes,
Safe distance from application area
d) Sand buckets are provided in transformer yard.

8.0 FIRE DETECTION & ALARM SYSTEM
8.1
System Design
a) Complete FDAS is to be designed and installed as a fully functioning Life Safety
System.
b) In case of fire, an audio-visual fire alarm is to be generated in the respective plant
operating office, security. Also signals are initiated to operate respective hooters
located at appropriate places in the plant When one of the detectors located in an
area senses the fire, it shall send alarm signal to the FACP. The FACP shall verify the
alarm condition by sending a reset signal to the detector. After a predetermined time
(which is field settable), if the detector is still in alarm condition, the FACP shall
confirm it as alarm condition. In such case Audio-visual fire alarm shall be generated
from the FACPs to which the alarm initiating device is connected. Provision is
available for manually activating FDAS through manual call points.
c) The selection of type & number of fire detectors are to be based on type of
combustible content & ignition source, type of environment & type of risks involved.
d) The locations of the individual fire detectors in the system have to be such that total
area under consideration is covered under the area of coverage of the detectors,
without any blind zones.
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e) Each detector/device shall have a built in fault isolator base so that if a fault occurs in
it, only that detector/device is isolated and the other detectors/devices continue to
function normally. Once the defect is rectified at the faulty equipment, the
detector/device automatically reconnects.
f) The loop size is to be designed such that any loop is not loaded more than 80% of its
capacity (including 20%spare) so that FACP functions without failing in severe fire
condition.
8.2
System Description
a) The Fire Detection and Alarm system shall be fail safe and is required to analyze the
fire signal and initiate the hooters within the time stipulated by NFPA.
b) Every area requiring fire protection can be split up into Zones, to help in exactly pinpointing the location of fire. Small rooms enclosed by walls on all sides are
considered as a separate zone in an area. If an area requiring fire protection is very
significant (say an area on a particular floor level of a building) it can be split into
suitable number of zones depending on the location of walls or criticality of the area
to be protected or other structural obstructions. In an addressable system, each and
every detector can be configured as separate fire zone and it shall be possible to
address the exact location of fire during an incident. Hence the concept of fire zones
implies each detector in case of an addressable system.
c) In a particular zone if fire is detected, then the air-conditioning / ventilation system /
other forced ventilation systems of that area is switched off.
d) The FDAS comprises of the following components:
(I)
(II)
(III)
Fire Alarm Control Panels (FACPs).

Fire alarm repeater panels (FARPs)
Alarm initiating devices such as detectors, Manual call points etc.
e) The basis for deciding the quantity of FACPs, Detectors are as given below:
Fire Alarm Control Panel (FACP):
(i)
The quantity of FACPs is decided based on the total number of devices

connected to it. And each FACP has provision for upto 8 loops. Each loop can
be loaded with 125 detectors / devices. . Length of fire alarm loop cable from
FACP and return to FACP shall be 2.5 kms:
S. No
Name
FACP
of
Location of FACP
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a)
FACP-01
Tube Manufacturing Plant Office
a)
FACP-02
Chain Manufacturing Plant Office
(ii) All the above panels will have the provision to be expandable upto 8 loops.
However, the number of loop cards ordered will depend on the exact
requirement.
(iii) The system is to be designed such that occurrence of false alarm is reduced to a
minimum.
Fire alarm Repeater Panel (FARP) :
(i)
There is one FARP each located in Security room of Tube manufacturing Unit &
Chain Manufacturing Unit. This repeater panels displays the fire status FARP will
indicate where in the plant, the alarm originated & display the information such
as floor Elevation, Room no. and detector no. etc. It will be connected to FACPs.
(ii) It will also indicate the type of device initiated so that emergency personnel can
locate the fire quickly.
(iii) Each panel will have the facility to acknowledge the fire and silence the alarm.
The resetting facility will be available both from FACPs & from the FARP present
in the Security room.
f) The basis for selecting various detector types is discussed below.
a) Photo thermal Multi-criteria (Multi-criteria) detector:
Multi-criteria detector is a combination of optical smoke detector and heat
detectors. These can be provided in most of the areas such as office areas,
personnel rooms etc., to detect smoldering smoke generated due to burning of
furniture, clothes, PVC flooring, and short circuit conditions in electric cables.
Advantages:
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The advantage of Multi-criteria detector having is that it can detect both

smoke and heat simultaneously. The cost is almost comparable with the
optical smoke detectors. Hence this, multi-criteria detectors are considered.
b) Fixed temperature heat detectors:

Heat Detectors are used in areas where during a fire heat increases rapidly with very
little smoke. Also, areas where general fumes are present, smoke detection might not
be the right detection method since it may give rise to false alarm.
Principle of working:
It is designed with a preset fixed temperature trip point. These detectors will respond
to the fire condition when the temperature exceeds the fixed temperature setting.
Heat detector is characterized by the Grade Constant i.e. the maximum time in which
heat is sensed by detector.
Advantages:
Fixed temperature Heat detectors have greater resistance to adverse environmental
conditions (such as dust, fumes, etc) as compared to other type of detectors.
c) Hydrogen detector:
Hydrogen detector will be provided for Battery Rooms and other areas where
Hydrogen is present
d) Manual Call Point:
i)
Manual call point is of lift and pull down or push and pull down type. This is
provided within the buildings from where a person can give a fire alarm signal
manually to the FDAS. This can also be located in areas where other types of
detectors cannot be used Such as Plant Operating Area.
ii) It will be surface mounted.

iii) Each addressable manual call point will comprise of an electronic circuit built
into it to provide addressing capability and of reputed make.
iv) It will have a fault isolator base.
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v) Manual call point will be addressable and will continuously communicate its
operating conditions and healthiness to FACP and FACP will able to monitor
individual manual call point.
e) Hooter:
i)
Hooters will be conventional type & it will be interfaced to FACP through

control module so that each hooter will have individual address & control from
the FACP.
ii) It will be separately powered from FACP.

iii) Hooters will be mounted in various locations to generate audible alarm in
case of fire in the respective area.
iv) Hooter will sound automatically when any of the detectors in that area detects
fire condition.
v) Hooter will have two tones i.e Fire and All clear.
f) Addressable Monitor Module:
i)
Addressable monitor modules will be provided for all nonaddressable/conventional detectors such as Hydrogen detector to assign an
address to such detectors and to be compatible with the FACP.
ii) It will have fault isolator base

g) Control Module:
i)
It will provide dry contact output for activating hooter, a variety of auxiliary
devices, typically used where control or shutting of external equipment is
required. In, Air handling units, supply air fans will be switched off in case of
fire. These control actions will be initiated by FDAS will be executed by
control module. Potential free contacts will be wired to individual equipment
from control module and the contacts can also be wired to MCC to trip their
respective AHUs.. These contacts are fail safe and will be supervised
contacts and will be monitored by the FACP.
ii) Control module will be loop powered and provided with fault isolator base.
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h) Repeat Response indicator

It will be a Multi colour multi status single LED type indicator repeating the
indication of detector during an off normal condition. It will be provided for all the
detectors placed above the false ceiling or for the detectors whose inbuilt
indicators view is obstructed by any of the services.
g) Cables:
i)
Fire alarm loop cable of 2 core, armoured, 1.5 sq. mm, annealed tinned
copper conductor, PVC insulation, FRLS PVC sheathed, cables will be used
for connecting the individual detectors and FACP.
ii) Communication cable of multi-core, 1.5sq.mm. , annealed tinned copper

conductor, FRLS PVC sheathed cables will be used for RS485 interface
between FACPs, FACPs to Fire alarm repeater panel, ring network between
FACPs.
8.3
Electrical Power Supply for Fire Alarm Control Panels:

i)
The system is provided with power supply from 240 V AC, 50 Hz single phase,
Uninterruptible power supply system. FACPs will function during normal power
failure conditions for the period of half an hour, for which the adequate external
battery back-up is provided.
ii)
The body of all the panels are connected to the common safety grounding grid.
8.4
Design Parameters
a)
For calculating the number of detectors required in a particular area / room, and for
the spacing of detectors, IS 2189 is used. FThe locations of fire detectors are to be
coordinated with other services such as air-conditioning grills, light fittings, cable
pans, ventilation ducts, etc.
b)
In locations wherever false ceiling/false flooring is envisaged, detectors are provided

both above false ceiling & below the false flooring. The detectors are installed above
the racks and at the air extraction point.
c)
Manual call points are provided in all exits points and staircases. Manual call points
are also located at easily accessible areas, in such a way that the occupants dont
have to travel more than 30 meters from any position in order to initiate an alarm.
d)
Manual call points are installed 1.4m above finished floor level for easy access.
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The Hooters: Audio annunciation for the evacuation of people is provided. The
evacuation alert signal is in accordance with relevant codes and standards.
Remote response indicators (RRI) are provided for detectors where it cannot be seen
distinctly. For detectors located above/below false ceiling/flooring or detectors whose
clear sight is obstructed by cable trays, etc. require RRIs.
8.5
Interface with Other System
8.1
When FDAS raises a fire alarm, following operations in the below mentioned systems
occur. Proper Interfacing is done to accomplish the operations:
8.2
Air-Conditioning and Ventilation System:. In case of fire, the alarm signal will be
generated by FDAS. The signal will be transmitted to the Local control panels of air
conditioning and ventilation system or by using control module to switch off the
supply and exhaust air fans.
9.0 INSTRUMENTATION AND CONTROL (I&C) SYSTEM REQUIREMENT

A relay based Local Control Panel shall be provided for local operation and
monitoring at fire water pump house. The local control panel shall house the
following.
a)
Alarm Annunciator
b)
Local/remote & selector, auto/manual switch, start / stop push buttons &
indicating lamp for start/stop/trip status indication for the jockey pump, main
pump.
c)
Test reset and acknowledge push buttons.
d)
Hooter
e)
Necessary relays for execution of interlocks and contact multiplication for

alarm in fire officers room
f)
Remote input-output unit for communication of all fire protection signals from
the local control panel to the main control room on RS485/Ethernet protocol.
The annunciator shall be microprocessor based, split type with alarm windows
mounted on front door and electronic modules inside the panel. Potential free
contacts shall be wired up to the terminals inside local control panel for each of the
alarm. These potential free contacts shall be used to repeat the alarm in fire officers
room. The panel will be provided with 230V AC from reliable supply from UPS, any
other voltages required shall be derived within the panel.
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Following alarm shall be annunciated:

a) Jockey pump tripped on overload
b) Jockey pump in manual mode
c) Main fire pump running
d) Main fire pump failed to start
e) Main fire pump in manual mode
f)
Engine driven standby fire pump running
g) Engine driven standby fire pump failed to start

h) Engine driven standby fire pump in manual mode
i)
Engine drive system in trouble
j)
Engine driven pump battery charger failure
k) Low pressure in the discharge header of the system

l)
AC to DC converters 1 failed
m) AC to DC converter 2 failed
n) Alarm valve operation
o) Deluge valve operation
10.0
FIRE EXIT & ASSEMBLY POINT

The plant areas and office areas are provided with emergency fire exits to ensure a
travel distance of minimum 30mtrs at any point in the building during any emergency.
Separate assembly points are provided for chain unit & tube unit for assembly during
emergency and for further instructions.
The emergency fire exits are provided as per NBC norms. Emergency evacuation
procedure will be finalised for the plant and frequent mock drills will be conducted for
providing training to all employees.
Photo-luminescent signages will be provided in the building to show the direction of
exit in case on emergency.
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CODES & STANDARDS

Requirements of Fire safety Installations & Life Safety Measures for various types of
occupancies issued by Tamil Nadu Fire & Rescue Services Department.
NBC
National Building Code
Hydrant System
Fire Protection Manual issued by Tariff Advisory

Committee
Spray System
Rules for water spray system issued by Tariff Advisory

Committee
Sprinkler System
Sprinkler Regulations
Committee
IS: 1239 (Pt-1)
Steel tubes, tubulars, and other wrought steel fittings:

Specification
IS: 3589
Spec for steel pipes of sizes 200mm NB & above pipes
IS: 636
Reinforced Rubber Lined Hose (Type-A)
IS: 5290
Hydrant Landing Valves
IS: 9972
Automatic Sprinkler Heads
IS 2190
Selection, installation and maintenance of first-aid fire

extinguisher
IS: 940
Specification for portable fire extinguisher, Water type
IS: 2878
Specification for fire extinguisher, carbon dioxide type
IS: 13849
Specification for fire extinguisher, ABC type
IS: 10204
Specification for fire extinguisher, Foam type
IS: 2189
Selection, Installation and Maintence of Control and

Indicating Equipments for Fire Detection and Alarm
System
IS 11360
Specification for smoke detectors.
UL-521
Specification for heat detectors
BS 5839
Code of practice for fire detection and alarm system in

building.
issued
by
Tariff
Advisory
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TATA CONSULTING ENGINEERS LIMITED

PROPOSED GREEN FIELD PROJECT FOR

TATA CONSULTING ENGINEERS LTD.

FILE NAME: TCE.6769A-ME-608-CN-03

TATA CONSULTING ENGINEERS LIMITED

TATA CONSULTING ENGINEERS LIMITED

Entire Chain & Tube manufacturing plant area.

B) High Velocity Water Spray System (HVWS):

TATA CONSULTING ENGINEERS LIMITED

3.0 DESIGN OBJECTIVES

Recommend optimum fire protection / fighting systems for various facilities as

TATA CONSULTING ENGINEERS LIMITED

5.0 INPUT DATA

Parking areas, Security

Product Testing & Development / Admin Office

Heat Treatment Shop

Parts Production Shop

Maintenance / Central Tool Room & Office

Maintenance Office / Stores

M/C Service / Repair

Mechanical / Plumbing Contract

HSD & Methanol Underground Storage

Canteen /Rest Room / Lockers

Parking areas, Security,

TATA CONSULTING ENGINEERS LIMITED

Admin / Training Hall

Switchyard, Transmission Corridor, Substation

HSD Storage Area

Diesel Generator House

Canteen / Gym / Rest Room

ETP & STP

Stores, Comp Room, Tool Room

6.0 SYSTEM DESIGN

Water based fire protection systems

TATA CONSULTING ENGINEERS LIMITED

Therefore, the hydrant system consists of:

Hydrant Valve (External)

Hydrant Valve (Internal)

Total Hydrants Points as per TAC

High Velocity Water Spray System

Transformer dimension including radiator &

TATA CONSULTING ENGINEERS LIMITED

Medium Velocity Water Spray System

Bullet dimension (Approx.)

Surface area of bullet in m

Design density for spray system

Flow required in lpm for one LPG mounded bullet

Total flow required in lpm for three LPG bullets

Supplementary Hose stream demand in lpm

Total flow required in lpm with 10% Margin

Total flow required for one tank in m/hr

6.2.4 Fire water Pumps Capacity & Head selection

Water storage as per TAC rule shall be:

TATA CONSULTING ENGINEERS LIMITED

Jockey Pump capacity

273 m3/hr. @ 70 mWC total head

273 m3/hr. @ 70mWC total head

10.8 m3/hr. @ 70 mWC total head

Pressurised fire hydrant system is provided for the entire plant.

Therefore, the hydrant system consists of:

TATA CONSULTING ENGINEERS LIMITED

Hydrant Valve (External)

Hydrant Valve (Internal)

Total Hydrants Points as per TAC

Fire Detection & Protection System

Fire Detection & Protection System