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OPERATION & MAINTENANCE MANUAL FOR HIGH VELOCITY WATER SPRAY SYSTEM AT RH DEGASSER & LHF PACKAGE OF VIZAG STEEL PLANT (VISHAKHAPATNAM)
FIRE FIGHTING CONTRACTOR

MEHTA & ASSOCIATES FIRE PROTECTION SYSTEMS PVT. LTD.


210, Pushpam Complex, 100 Ft. Anand Nagar Road, Opp. Seema Hall, Ahmedabad 380 051 Ph. :- 079 - 26933377/78/79, Fax :- 079 2693 0909 Email : info@mehtafire.com; mktg@mehtafire.com Web : www.mehtafire.com

M ASS

PRINCIPAL CONTRACTOR

SMS INDIA PVT. LTD. (SMS GROUP)


CONSULTANT

M.N. DASTUR & COMPANY (P) LTD.


CONSULTING ENGINEERS, KOLKATA ULTIMATE CLIENT

VIZAG STEEL PLANT (RASHTRIYA ISPAT NIGAM LIMITED)

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O&M MANUAL FOR HIGH VELOCITY WATER SPRAY SYSTEM AT RH DEGASSER & LHF PACKAGE OF VIZAG STEEL PLANT (VISHAKHAPATNAM) INDEX
SR.N O 1 2 3 4 5 6 8 9 10 DESCRIPTION INTRODUCTION PUMP HOUSE EQUIPMENTS & RESERVOIR PRESSURISATION OF SYSTEM SYSTEM WRITE-UP HVW SPRAY SYSTEM REQUIREMENT OF MAINTENANCE MEASURE WHEN SYSTEM IS TEMPORARILY INOPERATIVE ANNEXURE-I - INSTALLATION, OPERATION AND MAINTENANCE MANUALS OF VALVES ANNEXURE-II - INSTRUCTIONS TO PUMP OPERATOR ANNEXURE-III - CHECK LIST FOR FIRE WATER PUMP HOUSE PAGE NO. 3 4 5-6 7-8 9-10 11 12-13-14 15-16 17

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INTRODUCTION The Manual contains essential information regarding operation and maintenance of High Velocity Water Spray System at RH Degasser & LHF package of VIZAG STEEL PLANT (VISHAKHAPATNAM).

TRANSFORMER AREA IS PROTECTED BY THE FOLLOWING SYSTEM:-

(A)
1.

BY HVW SPRAY SYSTEM 2 Nos. of 24 MVA Transformer

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PUMP HOUSE EQUIPMENTS & RESERVOIR: The following Pump Sets are provided to cater the water requirement of the System.
1. 2.

HVW Pump: Capacity 137 M/hr at 70 MWC Head @2900 RPM Qty.1 No. Diesel Engine Driven Standby Pump: Capacity 137 M/hr. at 70 MWC Head @1800 RPM Qty.1 No. Jockey Pump: Electric Motor Driven Jockey Pump of capacity 10.8 M/Hr. at 80 MWC Head / 2900 RPM. Qty. 2 Nos.

3.

OTHER EQUIPMENTS:HYDRO PNUMATIC TANK AIR COMPRESSOR Qty. 2 Nos. DIESEL TANK PANELS:In Pump House; P1 P2 P3 - Motor Control Center for Pump - Diesel Engine Control Panel - Battery Charger Panel : Capacity 3 M

: Capacity 14.58 Cubic Mtr/hr @ 12.3 hg/cm, : Capacity - 175 Ltrs

FIRE WATER RESERVOIR: No. of Compartments Total Capacity : 2 : 297 M

Fire Water Reservoir and Pump House are constructed above ground. Suction of the pumps is from bottom of the Water Tank, and hence positive suction is ensured to the Pumps.

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PRESSURISATION OF THE SYSTEM Water based firefighting system will be pressurized at approximately 8 kg/cm2 through Hydro-pneumatic tank and compressor. The hydro pneumatic tank will be filled with 2/3rd of water and 1/3rd of High pressure air. In normal condition minor leakage of water from the system will be supplied from hydro pneumatic tank. Water level in the H.P tank will be maintained through the Level Switch LS7 and LS8 by running jockey pumps (PP3 & PP4). LS7 is used to start the Jockey Pump and LS8 is used to stop the jockey pump automatically. If jockey pump01 (PP3) fails to start within specific time then standby Jockey Pump02 (PP4) will be started automatically through hard wired interlocking. In no case both jockey pumps will run at a time. Also jockey pump will be provided with level guard for preventing dry running. Air Pressure in the H.P tank is maintained through PS 01 and P.S 02. PS 01 will start the Air Compressor 01 (operating) (07 Kg/Cm2) and if due to any reasons Air Compressor 01 do not start within specific given time it will result further pressure drop in the system and the same will be sensed by PS 02 (stand by) (06 Kg/Cm2)and will start the Air Compressor 02 automatically. Air compressors will be stopped at (08 Kg/Cm2) through PS 01 and PS 02. In no case both compressor will run at a time. In the condition of fire in the protected areas, it will cause fall in pressure drop in the system (i.e. by opening of Deluge Valve of HVWS system). At that time HP tank will not be able to maintain the system pressure and will cause gradual pressure drop in the system when the system pressure will fall to preset value (5.5 Kg/Cm2) and will be sensed by pressure switch PS5 in pump discharge line, it will give annunciation to Fire Alarm Control Panel for Header Pressure / system pressure Low. When the system Pressure will fall to a preset value (05 Kg/Cm2) it will be sensed by PS 03 and will start Motor Driven HVWs Pump to cater the water requirement. Pump will be stopped manually only. Due to some reasons if the Motor driven HVWs pump does not start or if it is not generating the required pressure; it will cause further pressure drop in system and when pressure reaches to a present low value (04 Kg/Cm2) and will be sensed by P.S 04 will start the Diesel engine driven HVWs pump automatically to cater the water requirement. In no case both electrical driven and diesel driven pump will run at a time. Both the pumps will be provided with water level guard for preventing dry running. The Main Pumps are to be stopped manually after the Fire Fighting operation is over.

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CONTROL SEQUENCE OF EQUIPMENTS EQP . NO.


LS 1 TO LS6

START
FOR AUTO ACTUATED VALVE OF WATER TANK FIDDING LS7 FOR JOCKEY PUMP-1 START 7.0 KG/CM 6.0 KG/CM 5.0 KG/CM 4.0 KG/CM 5.5 KG/CM

STOP
FOR AUTO ACTUATED VALVE OF WATER TANK FIDDING LS8 FOR JOCKEY PUMP-1 STOP 8.0 KG/CM 8.0 KG/CM MANUAL MANUAL -

TITAL

REMARK

LS7 LS8 PS 1 PS 2 PS 3 PS 4 PS5

IF WATER LEVEL OF THE FIRE WATER TANK IS LOW-LOW AUTO ACTUATED THEN ANY EQUIPMENT OF THE VALVE FIRE WATER PUMP HOUSE DOES NOT START AUTOMATICALLY. IF JOCKEY PUMP-1 DOES NOT JOCKEY PUMP 1 START WITHIN SPECIFIC TIME JOCKEY PUMP 2 THEN JOCKEY PUMP-2 WILL START AUTOMATICALLY. AIR COMPRESSOR 1 AIR COMPRESSOR 2 HVW SPRAY PUMP DIESEL ENGINE DRIVEN STAND BY PUMP TO GIVE ANNUNCIATION FOR LOW PRESSURE IN MAIN DELIVERY HEADER

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SYSTEM WRITE UP
HIGH VELOCITY WATER SPRAY SYSTEM The Transformer is protected by Automatic High Velocity Water Spray System. It consists of Deluge Valves, Isolation Valves, Inlet Strainers, Nozzle Network and Quartzoid Bulb Detector network all around the Transformer. The High Velocity Water Spray System consists of two networks of Piping - One network for Quartzoid Bulb Detectors (QBD) and the other for Water Spray Nozzles. The Detector network is charged with pressurized water supply from upstream side of Deluge Valve through a restriction Orifice. The other network having Water Spray nozzle is connected to the down stream side of the Deluge Valve. This network carries Water Spray Nozzles strategically located around the Transformer for required water distribution over the entire surface of the Transformer and connected piping. The QBD operates at 79 Deg. C. The Detector network is kept pressurized with the System line pressure and the network is charged with water. The Detector pressure holds the seat of Deluge Valve in closed position. In case of fire when any Detector is rupture, the pressure in the line drops. This reduction in pressure will drain the pressure in Control Chamber of the Deluge Valve. The System line pressure acting on the clapper of the Deluge Valve, forces seat to open and allow flow of water to the Nozzle network. Deluge Valve can also be actuated by means of Push Button station. This facility allows remote operation of Deluge Valve with Solenoid Valve. A Manual Pull Box is provided adjacent to the Deluge Valve to facilitate operation of Deluge Valve manually. OPERATION OF SYSTEM: The HVW Spray System is fully automatic in operation. In case fire occurs in one of the Transformers protected, the temperature may rise in surrounding areas. When the Temperature reaches at a pre-determined value (79 Deg. C) at the Quartzoid Bulb Detector, the bulb will rupture. This releases the pressure from the detection line. The loss of pressure in detection line causes pressure drop in Control Chamber of Deluge Valve. This causes the seat inside the Deluge Valve to open and hence the water flow is established through the Deluge Valve which is eventually sprayed over the surface of the Transformer through the Spray Nozzles so as to completely envelope the equipments. The starting of the HVW Spray Pumps is also automatic. It is actuated by a pressure switch which is mounted on the discharge header of the pumps in Pump House. When pressure in discharge header falls to a pre set value (5.5 Kg/Cm) due to opening of Deluge Valve Main Motor driven HVW Spray Pump

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will come into operation automatically. However, the pump has to be stopped manually on completion of fire fighting operation. ******** MANUAL OPERATION OF THE SYSTEM: Though the HVW Spray System is automatic in operation, in case of emergency the system can be operated manually by the following means. A. The Manual Pull Box may be open and the quick opening valve shall be turned by 90 Deg. This will drain the pressure in Control Chamber of Deluge Valve. Thus Deluge Valve can be opened manually by means of Manual Pull Box. B. The Push Button of Local Control Panel located near the Deluge Valve may be operated. This will open the Solenoid Valve provided on the detection piping. The Deluge Valve will open due to imbalance of pressure. RE-SETTING OF THE SYSTEM: After operating of the HVWS System, it has to be reset by taking following steps. A. The Isolating Valve in upstream of Deluge Valve should be closed. B. The 15 mm dia Valve in the priming line of Deluge Valve should be closed. C. The 50 mm dia Drain Valve of the Deluge Valve should be opened and all water drained out, and valve should be closed again. D. If the System has been actuated automatically, then the Detector (s) with broken bulb should be replaced. E. If opening the valve of Manual Pull Box has actuated the System, the same should be closed. F. If the System has been actuated by opening the Solenoid Valve (through Local Control Panel Push Button) then ensure that the Solenoid Valve should be closed (de-energized). G. Now open the 15 mm dia Valve which was closed as per the step (B). H. Wait for 5 minutes. I. Now open the upstream (Sluice) valve which was closed in step (A).

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J. Now the Deluge Valve is reset.

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REQUIREMENT OF MAINTENANCE:
The following recommendations effectiveness of the system. FIRE FIGHTING PERSONNEL:
1.

should

be

complied

to

enhance

the

As the efficiency of the HVWS Systems and other internal appliances depend upon the manner and speed with which they are brought into use and the ability with which the effort is directed. A squad consisting of Watch and Ward Personnel, Fire Pump man and Departmental Supervisors and/ or operators trained in the operation of the Fire Service shall be formed. The number of persons constituting the squad shall necessarily depend upon the size of the risk but in no case shall be less than four trained persons be available at all time during the day or night.

2. Squad leaders shall preferably be well trained and their usefulness will be considerably enhanced if they reside on the premises.
3.

Squad personnel shall be provided with necessary clothing and equipment including Helmets, Fire Axe, and Belts, preferably Gum Boots.

4. A Muster Roll showing the duties allocated to each member of the brigade shall be prepared and copies shall be supplied to each squad leader as well as shall be pasted in convenient places throughout the premises, for easy & quick reference in case of emergency. 5. Practice drills shall take place weekly and wet drills shall be carried out at an interval of not more than a fortnight. 6. A register shall be kept showing details of all practices and defects reported in the installation. This register shall be opened to examination by responsible inspectors.
7.

The services of the Pump men could be profitably utilized for the maintenance of all Fire Fighting Appliances including Hand Appliances. He shall also be thoroughly conversant with the locations of all appliances, so that in an eventuality he would be of assistance to the factorys and towns fire brigade.

8. Keys of all doors in the factory premises shall always be available at the Main Gate.

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9. It is recommended that Fire Pump Room and the Main Gate of the Factory premises be connected to all manufacturing section/departments and major risk areas by internal telephone system. This would save valuable time in an emergency, for alerting the Fire Fighting Personnel and the Pump men. ********

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PUMPS:
1. A Trained Pump man shall always be available in all shifts and at all hours of the day and night to operate the Fire Pumps as and when required. 2. All Pump sets shall be run for at least five minutes every day. 3. All Pumps and Valve Glands shall be maintained in efficient working condition and the packing renewed as required to maintain efficiency. 4. All working parts shall be kept clean and lightly oiled as cleanliness greatly adds to efficiency. Any necessary repairs shall be taken on hand and carried out immediately. 5. The bearing grease caps shall be checked once every week & refilled with fresh grease if necessary. 6. Starter contacts shall be cleaned once every week. 7. Insulation resistance of Pump Motor circuit shall be examined once every six-month and record of results shall be maintained. 8. All cut-off Valve shall be thoroughly overhauled annually to remove sludge and other foreign matter collected in the valve seating. 9. All cut off valves shall be operated and oiled/greased if necessary, once a month. DIESEL ENGINE: 1. Engine shall be tested at least once in a week. 2. Check whether the engine is cooled.
3.

Check Battery once in a week, if required add distilled water.

4. Diesel Tank should be full at all the time.

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MEASURE WHEN INSTALLATION IS TEMPORARILY INOPERATIVE


When installation is expected to remain in-operative for a period exceeding 24 hours, prior sanction of the Fire Brigade Authority should be obtained. When any component of the HVW Spray Systems are to be replaced for any reason whatsoever, the entire HVW Spray System shall not be rendered inoperative, but the particular section only shall be isolated by closing the necessary cut off valves. However, if it is not possible to complete replacement before night fall, the cut off valves shall not be left closed overnight. Instead, blank flanges shall be provided at the point where the component has been removed, so that the entire system other than the component which has been removed would remain operative throughout the night. If the pump is expected to be in-operative for more than 72 hours, every effort shall be made to connect the service water supply to the HVW Spray Systems for the duration the pump is in-operative. If the HVW Spray Systems are to be extended, the extended portion shall be first laid and, thereafter the connection between the existing system and the extension shall be carried out expeditiously, so that the entire system is not left in-operative overnight.

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ANNEXURE-I INSTALLATION, OPERATION & MAINTENANCE INSTALLATION:


1.

OF VALVES:

One should take care in handling the valves, valves should not be dropped on the ground, and not to bump valves against anything. Especially be careful not to damage the flange surfaces, butt-weld ends, socket weld ends etc. Make sure that all valves and piping materials are clean and free from dust, rust and scale. Blow out all pipe and fittings with compressed air; remove protective covers from valve openings just before installing the valve. When installing flanged valves, make sure that the gaskets are cleaned and they are properly placed on the flange faces. Bolts should be stressed equally in opposing pairs during tightening the joints. Make all joints tight but do not over stress. when tightening packing and bonnet nuts. This is especially important

2.

3.

4.

Utmost care should be taken while welding the valves to pipe. Butt welded end should be proper. This is skilled welders job. Remove any foreign materials inside the connecting piping such as dirt sand, scale, metal chips, burrs and grit particles which damage valve seat. Install valves in the connecting piping so that the arrow head marked on the valve body coincides with the flow direction in the piping. After installation, it is good practice to clean the whole line, check carefully for leak, especially around the valve gland packing or flange connections. Tight the flange bolts if necessary. Even if the connection is tight, but still there is a leakage, then it is understood that the gasket is damaged. Remove the old gasket and replace with new one. Use proper type of wrenches for tightening the bolts, preferably torque wrenches. ********

5.

6.

7.

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OPERATION:
1. 2.

Allow the valves warm up gradually and then check all joints. Flush out the whole line thoroughly. Try to open and close the valve. If it operates with difficulty, it is understood that some internal parts are locked up, for example gate is not coming up smoothly in case of gate valve. In such cases the valves should be dismantled and repaired. For manually operated valves, turn the hand wheel, counter clockwise to OPEN and clockwise to CLOSE. However, it is marked on the hand wheel.

3.

4. Turn the hand wheel slowly in the initial opening.


5.

Never use too much FORCE in either opening or closing. If the hand wheel is tight and you want to use any tools, such as lever, spanner or pipe wrench, do not use too long one which gives too much moment and stress to the spindle and yoke. Do not close the valve too tightly.

DISASSEMBLING OF VALVES.
1. 2.

Prepare all necessary spare gland packing and jointing gaskets. Open the valve slightly by turning the hand wheel anti-clock-wise and loosen the gland. Put match markings on all valve body, bonnet, yoke and actuator. This helps to avoid mismatching of parts at the time of re-assembling. If the bolts and nuts are too tight, put the deep penetrating oil for some time and then un-screw the same.

3.

4.

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MAINTENANCE: Inspect whether all valves can be OPENED or CLOSED smoothly and whether any leakage. This should be done once or twice a year. Put lubricant (such as grease) into the grease nipple and spindle threaded part. When you find any defect or trouble, take following measures: a) The leakage starts from the gland packing. Tight the eye-bolt nuts slowly, even if leakage is not stopped, replace the old gland packing with the new one. Prepare required number of packing rings, and tight the gland for one ring after another. Packing should be fitted evenly in the stuffing box. Arrange packing so that the cut section shown in the figure of each packing comes at every 90 degree from that of adjacent one. b) For the leakage from the gasket. Tight the bonnet bolts and nuts. It is still insufficient or not effective disassemble the valve to inspect whether if there is any defect at the gasket contact surface. If you find defective contact surface then repair the same by welding and matching. Replace the old gasket. c) Difficulty and heavy moment in opening and closing. If lubricant (such as grease) does not help, disassemble the valve to inspect its interior.

d) For the leakage from the valve seat. Disassemble the valve. Remove disc and seat ring or wedge and seat ring. Inspect both, if the seating surface got scratches etc., re-machine them. Lap the same and replace.

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ANNEXURE-II INSTRUCTIONS TO THE FIRE PUMP OPERATOR.

It is desirable that at least one properly trained person should be available in every shift to assume the responsibility of Fire Pump Operator. He should be alert and watch the entire operation of the Pumps in general. The following points are only guide-lines to help him discharge his duties more efficiently.
1.

Ensure that the Pumps are in auto position. Ensure that electricity supply is always available to the panel. Ensure that the pumps start in the sequential operation as mentioned in the chapter SYSTEM WRITE-UP under the heading of PRESSURIZATION OF THE SYSTEM.

2.

3.

4.

During the fire fighting operation, the Pump Operator must be especially alert and in constant contact with the Fire Marshall.

5.

Ensure that Fire Water Reservoir is always full of water. On receipt of intimation from the Fire Marshall of having completed fire fighting operation, switch off the main pump and reset the system in auto operation.

6.

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DAILY CHECK: * * * Please ensure all isolation valves are open. Please check pressure reading on all gauges. Ensure availability of power supply at panel.

WEEKLY MAINTENANCE: * Put the lubricant into the threaded part of the spindle throat nipple for easy operation. * Put graphite powder with grease on each nut and bolt to avoid rusting. * Deluge Valve operation without discharge. Take trial of Deluge Valve by closing the Isolating Valve on the downstream side of Deluge Valve. The trial can be carried out by either of two manual modes for actuation of Deluge Valve. Mechanical actuation through emergency valve near Deluge Valve. Electrical actuation through Solenoid Valve operated from panel. Test the entire annunciation at the time of operation of Deluge Valve (for HVW).Reset the Deluge Valve properly as recommended in O & M Manual. MONTHLY MAINTENANCE: Take trial of the entire system by operating the Deluge Valve either through Emergency Valve near Deluge Valve or through electrical actuation by operating Solenoid Valve from panel. Test all the annunciations at the time of operation of Deluge Valve (for HVW). Reset the Deluge Valve properly as recommended in O & M Manual. Clean the Nozzle wherever required after taking flow test. Clean the Strainer every three month. Take flow test of the System every six months.

ANNUAL MAINTENANCE:

Check all the supports. Check damage to the paint. Apply paint wherever necessary.

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ANNEXURE-III
SHIFT: TIME: CHECK LIST FOR FIRE WATER PUMP HOUSE. 1. 2. Fire Water Line Pressure Testing of Pump: a) Jockey Pumps b) Main Ele. Pump c) Diesel Pump : Manual / Auto / Off - O. K / Faulty. : Manual / Auto / Off - O. K / Not O.K. : Manual / Auto / Off : 8 Kg/Sq.Cm.

(To be tested at least 5 min. and note timing) Tested from .................. to.................... 3. 4. 5. 6. 7. 8. Voltage of battery Diesel Tank Level Cooling water level in diesel pump Oil level in diesel pump Leakage/any other problem in fire water pump house Accident report if any from a) Time office b) Ambulance room Remarks if any : : : Name of Fireman: Signature : : : : : :

9.