2

Modernizing

CO
and Upgrading
Low Pressure
Carbon Dioxide
Fire Extinguishing
Systems

FIRE PROTECTION
Contents Introduction
Introduction Since 1940 tens of thousands of Cardox, Chemetron,
or Reliable Low Pressure CO2 Fire Protection Sys-
tems have been installed. A great proportion are still
Part I - STORAGE UNITS in service providing vital fire protection of key fa-
Refrigeration Changeover cilities.
Safety Relief Valve Recertification Over the years, new technology, changes in appli-
Evaluating Older Storage Units cable fire protection standards, and governmental
regulations have resulted in changes to system de-
sign, equipment function, and interface with the op-
Part II - CONTROLS eration of the protected facility. This publication
Upgrading System Controls offers guidance to ensure that your fire protection
system will continue to function safely well into the
Electrical Wiring Evaluation
next century.
Supervision of Pressure Operated Controls
At the heart of each system is the CO2 storage unit.
Cardox Valve Upgrades
In Part I, Storage Units, we will discuss:
Environmental regulations that phase out certain
Part III - SAFETY refrigerants.
Safety Upgrades
Recertification of safety relief valves promul-
gated by the Compressed Gas Association (CGA).
Personnel Availability
Recommendations for dealing with problems that
may indicate a concern with the effectiveness of
existing insulation.
Part II, Controls, outlines:
Changes in NFPA Standard No. 12, Carbon Di-
oxide Extinguishing Systems, which now re-
quires supervision (i.e., a means of indicating a
system/component malfunction).
How to upgrade existing systems to meet these
requirements.
Maintenance of vital control valves.
Reexamination of existing piping.
Part III, Safety, covers these safety concerns:
Conforming to Confined Space regulations while
at the same time ensuring against accidents and
fires when it is necessary to isolate protection
during maintenance.
Providing alarms and operating controls that con-
form to Americans With Disabilities legislation.
System retesting requirements and the desirabil-
ity of a periodic training/retraining program for
plant operators.
The Chemetron Engineering group, in concert with
a highly qualified distributor organization, is ready
to help evaluate your system to ensure that these vi-
tal needs for continued fire protection are met.
Part I STORAGE UNITS
Refrigerant Changeover
Most of the refrigeration systems installed before
1995 on Cardox, Chemetron, or Reliable style Low
Pressure CO2 storage units used ozone depleting re-
frigerants CFC-12 (R12) or CFC-502 (R-502). The
EPA has mandated a phase out of ozone depleting
refrigerants R-12 and R-502 by 1996.
While these refrigerants have been found to be ozone
depleters, Chemetron does not recommend chang-
ing the refrigerant in any storage unit that is operat-
ing properly without a loss of refrigerant. There is
no technical reason for change. However, it is pru-
dent to plan for replacement before it becomes an
urgent matter.
If the decision is made to change refrigerants, the
change should be to HFC R-404A (Suva HP62 or
FX70). The use of HFC-134A is not recommended,
as this requires an evaporator temperature above -
10F (-23C). The CO2 unit operates best with an
evaporator temperature near or below -10F (-23C).
Where practical, refrigerant changeover involves:
a) Changing lubricant oil. Old oil residue in new
oil should be 2% or less. Use of a lubricant ap-
proved by the condensing unit manufacturer is
mandatory. (Obviously, the refrigerant must meet
the manufacturers requirements as well.)
b) Changing the expansion valve.
c) Changing the filter/dryers.
d) Calibrating refrigeration pressure safety controls.
e) Possibly adding a pressure relief valve on the
compressor crank case.
f) Purging the coils at least 3 times to remove any
old oil.
g) Complying with the condensing unit
manufacturers recommendations on pressure
controllers, anti-flood-back pump down cycles,
and liquid stop solenoid valves.
Here are some basic guidelines for refrig-
erant changeover:
1. All work must be done by refrigera-
tion technicians, Class 2 or higher.
2. Retrofitting units with compressors
manufactured before 1973 is not rec-
ommended (per U.L. Standard U.L.
2170-2172 for field conversion/retrofit
to alternate refrigerants). The materi-
als in these older units have not been
evaluated for compatibility with R-
404A.
3. Retrofitting condensing units smaller
than 2HP is not recommended. Due to
cost effectiveness, replacement is rec-
ommended.
For points 2 and 3 above where replacement
of the condensing unit is needed, the evapo-
rator coils in the storage unit vessel must
be large enough for operation with the new
refrigerant. Consult Chemetron Engineer-
ing for information.
Safety Relief Valve Recertification
It is vital that safety relief valves protecting refrig-
erated CO2 pressure vessels function properly. To
ensure their reliability, these valves should be tested
and recertified periodically. Reference documents
from the Compressed Gas Association are:
S-1.1, S-1.2, S-1.3
- Pressure Relief Devices
G-6.1 (1986)
- CO2 Systems At Consumer Sites
For your reference, paragraph 6.2.3 of G-6.1, which
addresses relief valve testing, is reprinted on the back
page of this publication.
Fire system storage units below 13 ton capacity use
relief valves in pairs and a switching valve. One
valve is always connected to the vapor space of the
CO2 vessel. The switching valve is used to switch
over to the second valve, depressurizing the first
valve to allow for service.
Larger storage units were sometimes also built with
double valves. Other models had a single pilot op-
erated relief valve. Later models have a provision
for testing this single valve without taking the unit
out of service. For those, the manufacturers test
procedures should be followed. Contact Chemetron
Engineering for guidance on those that cannot be
tested without emptying the storage unit.
Evaluating Older Storage Units
For your reference, paragraph 6.2.2 of CGA docu-
ment G-6.1, which addresses storage unit inspection,
can be found on the back page of this publication.
Various construction methods were used to fabricate Storage unit pressure vessels produced prior to 1976
Low Pressure CO2 units over the years. All were were probably constructed of SA-212 or SA-515
intended to ensure a vapor seal to keep air (with its carbon steel, which do not meet current code require-
inherent moisture) from coming in contact with the ments. There is no problem with keeping these units
cold surface of the pressure vessel. Maintenance of in service as long as there are no problems as de-
the insulation is an important part of an overall main- scribed above.
tenance program.
However, Compressed Gas Associations position
The insulation must be kept dry to ensure effective- statement PS-5-1992 states, among other cautions,
ness. If any older unit shows cracking or a breach in that;
the insulation covering or housing with resultant
moisture or ice formation, there is a problem. Mois-
Those that require overhauls, major
ture is most likely to collect in the bottom of the
repairs, or show sign of corrosion
storage units insulation jacket. Excessive opera-
should be considered for scrapping
tion of the refrigeration system may also be a symp-
rather than extending their service life.
tom of trouble.
Correction of this problem is mandatory. Chemetron
can provide qualified individuals to help determine Note: The fire system outlet (dip tube) and fill line
the extent of the problem. This usually involves re- connections are a part of the pressure vessel. If ex-
building or replacing the unit. tensive corrosion is shown, then replacement is prob-
ably necessary.
On units smaller than 13 - 14 tons (1 1,800 12,800
Kg), it is often cheaper to replace the entire storage
unit rather than replacing the refrigeration and insu-
lation components.
Part II CONTROLS
Upgrading System Controls
Electrical Supervision
For many years, systems that were electrically con-
trolled utilized the power that was available at the
site. The only admonition was that the power was
to be from a noninterruptible source. Thus, a fire in
the protected area and the mandatory shutdown of
potential ignition sources and/or ventilation would
not de-energize the CO2 system controls. Thus, many
systems operated on 110 volt AC power. Numerous
systems were installed in mills or power plants where
an emergency power supply (usually 125V or 250V
DC) was available.
Fire alarm systems (only required to initiate a sig-
nal) used proprietary batteries; circuits were electri-
cally supervised. Loss of power, an open circuit, or
a ground fault was identified when it occurred, mak-
ing alarm systems much more reliable than the com-
parable CO2 system controls. On some CO2 sys-
tems, higher voltage DC electrical controls were
supervised, but this was an exception rather than the
rule. However, when many of the existing systems
were installed, the greater electrical energy required
to open CO2 control valves and sound a multitude of
alarms prevented the use of the lower voltages used
in fire alarm systems. Providing a 60 cell (125V)
battery for CO2 system control was expensive and
required substantial maintenance of the battery set.
Over the years, technological advances provided low
power controls and alarms, as well as batteries suit-
able to providing this power. This allowed a change
in NFPA Standard No. 12 (in mid-1980s) to man-
date supervision of CO2 system electrical controls.
A big jump in system reliability occurred as these
controls began to be used on every system.
For systems protecting critical facilities, it is highly
recommended that existing Low Pressure CO2 sys-
tem controls be upgraded to 24 Volt DC power with
Class B (2-wire) electrical supervision. This not only
increases reliability, but also improves safe opera-
tion of the system.
Note: Low Pressure CO2 system control requires the
opening and closing of control valves in a pro-
grammed manner. Control panels designed and ap-
proved or listed specifically for low pressure CO2
system service are required. The Chemetron Fire
Systems Micro 1-EV (illustrated in figure 1 ) is the
recommended control panel.
With the nonsupervised system, it was possible that
a fault in an alarm or detection circuit could blow
the fuse after a CO2 discharge had started. This
would leave no alarms for personnel warning and
could stop the discharge. Proper electrical super-
vision is designed to identify such a fault.
Upgrading involves changing control/alarm equip-
ment to 24VDC, providing a proper Chemetron panel
with batteries, and some minimal wiring changes.
Chemetron Engineering is available to help with
evaluating such changes.
Notes: Tee tapped wiring is not acceptable
on supervised circuits. This may necessitate rewir-
ing Lit manual release stations and detectors.
Most current 24VDC alarm circuits are reverse-
polarity type that require proper parallel circuit wir-
ing.
In addition, AC wiring for hose reels, nonsupervised
audible/visual devices, and shutdown circuits must
be isolated and run in separate wire-ways to avoid
ground faults in the DC wiring from induced or stray
voltages.
Electrical Wiring Evaluation
During initial system design, a strong attempt is made
to ensure that the electrical installation is suitable
for the environment in which it is installed, i.e., that
moisture, combustibles or contaminants do not have
the opportunity to affect the wiring. However, con-
ditions may have changed in the hazard over the
years and periodic reevaluation is appropriate.
If the detector wiring is in a hazard where a quickly
developing fire could affect it before the system op-
erates, special installations, such as silicone insu-
lated wire or mineral insulated (MI) cable, are ap-
propriate. Detector wiring retrofit should be con-
sidered during your electrical system reevaluation.
Supervision of Pressure Operated Controls
Since Low Pressure CO2 control valves open by
utilizing the inherent vapor pressure of the CO2 as
an energy source, the reliability of the pressure pilot
piping system is crucial. Our experience has shown
that this pilot piping network can be damaged, re-
sulting in an operational failure. Sometimes this
piping damage is not obvious, which motivated the
development of a scheme to monitor the system pi-
lot piping. This is now recommended by NFPA Stan-
dard No. 12.
The Chemetron design is described in the publica- Cardox Valve Upgrade
tion General Description, Chemetron Fire Systems
Chemetron (Cardox) pressure operated discharge
Low Pressure CO2 Supervisory Control Arrange-
valves need periodic maintenance to ensure they will
ment. Figure 2 illustrates this scheme. Again,
always open fully when operated. We recommend
Chemetron Engineering is available to help evalu-
that these valves be inspected at least annually in
ate modifications of existing systems to provide this
accordance with the procedures outlined in the pub-
important feature.
lication Inspection & Maintenance Procedures for
Chemetron (Cardox) Valves 1 through 6 Inches.
Frequent operation or installation in a hostile en-
vironment may necessitate more frequent inspec-
tion. Maintenance kits are available from Chemetron
Fire Systems to facilitate maintenance work.
This procedure is not intended to diagnose leakage
problems. Chemetron or an authorized distributor
can assist if leakage is suspected. The procedure is
intended to ensure proper valve operation and long
life. Only those fully qualified and trained should
work on these valves.
Piping Evaluation
Until about 1975, it was common to find Class 150
pipe fittings used on CO2 systems. In reconciling
the Universal Piping Code with traditional CO2 sys-
tem installation practices, it was determined that this
class fitting did not have the proper strength to handle
CO2 system discharges. Thus, their use was banned.
Therefore, system piping should be examined and
any Class 150 fittings replaced. They are recognized
by the thinner flange type boss at the fitting pipe
connection.
Nozzle Placement
In local application CO2 systems, protection is pro-
vided by the direct discharge Of CO2 on the equip-
ment being protected. The design of the nozzle, the
projection distance from the face of the nozzle to
the hazard surface, and the CO2 discharge rate de-
termine how much surface area that nozzle can pro-
tect. (An increase in area is allowed if the protected
surface is coated rather than a liquid surface.)
Local application CO2 systems are designed based
on the use of specific nozzles, as well as specific
placement and direction of discharge. If they are
moved in the field, gaps in the protection coverage
may result. If nozzles are interchanged with one
another, moved or removed, the protection system
may fail.
The nozzle code number is stamped into the nozzle
and shown on the system design drawings. Verifi-
cation that the proper nozzles are installed, and in-
stalled where they belong, is very important to good
fire protection.
Nozzles provided with covers, frangible discs, or
seals are used where it is necessary to keep material
from plugging nozzle orifices and piping. When
evaluating any nozzle arrangement, it is important
to see that this nozzle protection is intact. If any
nozzle is not so protected but requires same, this fea-
ture should be added.
Part III SAFETY
Safety Upgrades
It has always been recognized that CO2 flooding to
fire extinguishing levels presents a severe hazard to
any personnel who might inadvertently be in the area
where the CO2 is discharged. Precautions to be taken
to protect facility personnel are covered in NFPA
Standard No. 12 and the Chemetron publication
Carbon Dioxide Safety Manual. Over the years
we have learned how to enhance the safety aspects
Of CO2 system installation while government regu-
lations have also been promulgated in this regard.
Safety should be a key consideration in any sys-
tem reevaluation or upgrade. Incorporation of
these features may include:
a) Lockout Systems - When it is necessary for
maintenance, operating, or contractor personnel to
work in an area adjacent to or subject to CO2 flood-
ing, it is considered necessary to lock out the pro-
tection for that area while personnel are present.
Refer to OSHAs Lockout & Tag-Out Standard,
29CFR Part 1.910,146.
An adequate fire watch should be in place to deal
with any fire that might occur during system lock-
out. When protection is locked out, the following
should occur:
a signal of trouble should appear on the con-
trol panel.
a signal of protection impairment should be given
at a constantly manned location.
the equipment protected should be rendered in-
operable until the protection is back in service.
This is accomplished by interlocking the lockout
with the protected equipment.
Consult Chemetron Engineering regarding the best
way to handle this lockout. For critical Low Pres-
sure CO2 systems, Chemetron has used a double
block and bleed arrangement (as shown below) in
retrofitting the system.
b) Alarm Enhancement - It is imperative that
alarms provided to evacuate an area before a CO2
discharge, or to alert personnel that an area has al-
ready been flooded so they will not enter same, be
not only instantly recognizable, but also be impos-
sible to ignore. This can involve adding alarms that
are louder and have a distinctive tone quality from
any other alarms.
Older systems almost always depend solely on au- When revamping an existing system, a priority
dible alarms. Today, visual alarms are required. should be placed on evaluating the warning systems.
Warning signs* must be adequate and be provided
c) Hose Testing - NFPA Standard No. 12, paragraph
in all appropriate languages. Where CO2 may drift
1-1 0.2.1 requires that all system hoses and flexible
to an adjacent area or remain anywhere after a dis-
connectors be tested every five (5) years. A test re-
charge, it is appropriate to odorize* the CO2 dis-
quirement is given in the Standard. It is often best
charged. *See the Carbon Dioxide Safety
to replace a portion of older hose, retest it and keep
Manual for further information.
it as a spare. This prevents the need for taking the If the CO2 storage unit of an older system must be
protection system out of service for the time period emptied for maintenance, we strongly recommend
required to do the testing. that it be done by discharging the system in a prop-
erly planned manner with appropriate safety precau-
d) Retraining - When initially installed, almost
tions taken. Chemetron can arrange for trained com-
every Low Pressure CO2 system was given a full
pany or distributor personnel, with appropriate in-
discharge test. For hazards totally flooded, this veri-
strumentation, to help in this regard.
fied that the design concentration was reached and
indicated how long it was held. For hazards pro- Even if a retest is not done, continual training of
tected by local application, this test compared the plant personnel is critical. Chemetron and its dis-
actual discharge rate against the calculated rate. It tributor organization are available to help set up such
also showed whether or not the discharge covered a program.
all parts of the hazard.
Personnel Availability for System
Most importantly, full discharge tests provided an Enhancement and/or Evaluation
opportunity to show plant personnel what happened
during a discharge. It also made it possible to deter- Chemetron and its highly qualified worldwide dis-
mine where the CO2 might flow and provide for the tributor network stand ready to assist in any aspect
development of a proper safety program. It provided of a system enhancement. We will be pleased to put
valuable training for those working at the site. you in touch with the appropriate organization to
meet your specific needs.
Conditions may have changed for systems that have
been in service for some time, making a retest valu-
able in reevaluating the protection provided. More
importantly, personnel most certainly will have
changed. Therefore, a retest can be very important
as important as the test done at the time of the origi-
nal installation - by training those whose work takes
them into the protected area.
Make Chemetron your source for
fire suppression equipment
Low Pressure CO2
High Pressure CO2
FM-200
Control Panels
Chemetron Fire Systems products have been manu-
factured for more than fifty years and remain a vital
link to the gaseous agent fire protection market.
As a leader in the fire protection industry, we have
brought to market many innovative products and
extinguishing system design techniques. Chemetron
designs and manufactures Low Pressure Carbon
Dioxide, High Pressure Carbon Dioxide, FM-200,
and Water Mist fire suppression systems and elec-
tronic control panels. Chemetron Fire Systems also
offers design engineering and related technical sup-
port services for a wide range of applications. Cus-
tom developed computer programs aid our design-
ers in their design tasks, while allowing more accu-
racy and flexibility in your application.
Chemetron Fire Systems has established a world-
wide distribution network that provides engineering,
technical support, installation, commissioning, in-
spection and repair services. We are dedicated to
insuring that the reputation of special hazards fire
protection excellence built over the past 50 years is
maintained and enhanced.
Compressed Gas Association
Document G-6.1
6.2.2 The visible portions of the system, including
the storage container and appurtenances such as pres-
sure relief devices, the piping system, and the hose
lines, shall be inspected by a qualified individual at
least once a year or more frequently, as required.
Frost spots, leaks, or any other indication of a pos-
sible unsafe condition such as mechanical damage
or corrosion shall be corrected by repairs or replace-
ment of the faulty component.
6.2.3. Each pressure relief valve shall be tested at
least once every five years. If the start-to-discharge
pressure is not within the limits required for the ap-
plication and marked on the valve, it shall be re-
paired or replaced. Each pressure relief valve shall
be tagged and dated at the time of testing. Care shall
be exercised to avoid damage to pressure relief de-
vices. Care shall also be exercised to avoid plug-
ging by paint and other dirt accumulation on pres-
sure relief device channels or other parts which could
interfere with the functioning of the device.
The seller makes no warranties, express or implied
including, but not limited to, the implied warranties
of merchantability and fitness for a particular pur-
pose, except as expressly stated in sellers sales con-
tract or sales acknowledgment form.

Headquarters
4801 Southwick Drive
Third Floor
Matteson, Illinois 60443
Phone: (708) 748-1503
Fax: (708) 748-2847
1996 Chemetron Fire Systems. All rights
reserved. Chemetron Fire Systems, Cardox, and
Chemetronics are registered trademarks.