This 3D Animation video is an example of F.E. Moran Special Hazard Systems’ ability to design a comprehensive fire protection solution that meets the rigorous industry standards that regulate highly volatile transformers in power generating facilities. Their highly experienced designers meticulously design systems that are specialized for the individual environment, effectively mitigating the elevated risks associated with electrical equipment.

This system was recently restored and enhanced, with F. E. Moran Special Hazard Systems responsible for the calculations, design and installation of 6 grate foam nozzles with separate foam tank and piping.  The area of the installation had difficult access and required expertise in exterior foam suppression systems and flame detection.  F.E. Moran Special Hazard Systems had the necessary experience and knowledge and employed proper safety practices to effectively install the system and successfully complete the Fire Marshal’s test.

How Do Air Pockets Form Within a Sprinkler System?

There are a number of ways in which air pockets can develop within a water supply system.  When a new system is installed at a facility, it is initially filled with air at atmosphere.  It is the actions that are taken before the system is put into use that determine whether or not those pockets remain. Similarly, when repairs or outages occur, air is allowed to enter the system, which can create the same problems as when a system is first installed.  Another way in which air can accumulate in the system is from the water itself.  Over time, oxygen can separate from the water and form air pockets throughout the high points in the system. 

How Does Trapped Air Become a Threat to Sprinkler Systems?

 Regardless of how the air enters the system, these pockets will always naturally migrate towards the high points within the supply system.  As the air accumulates at these high points, it becomes more difficult for water to pass through these areas because the air acts as a restriction.  As the water is forced to pass through restrictions, its velocity will subsequently increase, until it has reached a high enough velocity to dislodge the air.  As the water is then stopped again by anotherhigh pointor the end of a main, the abrupt change in velocity can result in pressure surges or water hammer.     Another scenario that can result in water hammer is at the time of system start up. If water enters the empty pipe at a rate too quickly for air to escape, a surge of air pressure caused by the rush of water can create a water hammer.

 What Are the Consequences of a Pressure Surge?

 If caught early, minor pressure surges will have little effect on a facility’s fire protection system.  Gauges can indicate that a pressure surge is occurring and the appropriate measures can be taken to rectify the origin of the problem before it causes damage to the system. However, if a surge goes unnoticed and the issue escalates, the consequences can be destructive to the system and its effectiveness compromised. 

When a pressure surge occurs within a water supply system, pressure levels can reach upwards of 300 pounds per square inch (PSI) and become trapped on the system side of a sprinkler system valve.  The standard equipment associated with sprinkler systems in power generating and chemical processing plants typically have a rating of 175, in accordance with NFPA standards.  When sprinkler equipment is subjected to pressures that exceed their rating, equipment can fail and components such as valves and pumps are susceptible to damage.  Even if pressure surges of a lower magnitude occur repeatedly, the repeated stress cycles can weaken the system components.

Fire protection systems that suffer damage as a result of pressure surges are rendered ineffective while repairs are being made, putting the facility at risk until the system is functional again.  Alternatively, when damage is not immediately recognized, facilities are subjected to an even greater threat because it is possible that the faulty equipment will not be realized until proven ineffective in the event of a fire. 

Perhaps the most prevalent consequence related to pressure surges in sprinkler systems is the occurrence of false tripping of dry valves caused by surges.     False discharge that is triggered by a pressure surge is burdensome for plant staff and also takes a critical component of the fire protection system out of service.  Once discharge has occurred, plant staff must shut the system down and drain it, exposing the facility to risk while the system is being serviced.  Furthermore, if an accidental discharge occurs in freezing conditions and it is not immediately recognized, there is a possibility that pipes could freeze, causing long term impairments to the system. 

Beyond the issues related to damaged equipment and false trips, the overall performance of a dry sprinkler system can be impeded by the presence of air.  If the differential values of air pressure within the system pipes are skewed to compensate for surges, it can take longer for water to discharge in the event of a fire. Excessive air pressure and restrictions caused by pockets of air can result in slower delivery of water to the open head, allowing fires to grow in intensity, making them more difficult to control.

Safeguarding Fire Protection Systems from Pressure Surges

Taking into consideration all of the potential problems that can stem from pressure surges caused by trapped air in a water supply system, the best solution is preventing pressure surges from occurring altogether. There are different methods for preventing air from becoming trapped within a water supply system and the most effective solution involves careful planning that begins in the design phase of a project.

Because air inherently migrates to the high points of a system, underground designs that include many changes in elevation are more problematic than level designs.  One of the most critical measures that must be taken to prevent air from becoming trapped within the system takes place after the system has been installed and is being filled with water.  Lines should be filled slowly, allowing air ample opportunity to escape from the piping.   Additionally, hydrants and lead ins should be flushed in a systematic manner, beginning with the back of the system and moving towards the front, ensuring that every section of the system is thoroughly flushed before being put into use.  Air should be bled from all of the high points of the system to expel any remaining air that exists.  And, after the system is operational, these actions should be performed on a regular basis to prevent any accumulation of air within the sprinkler pipes.

Diligent Maintenance Mitigates Risk

The negative effects of neglecting trapped air within fire protection systems can be dire when the performance of the system is inhibited as a result.  Damaged equipment can not only be a costly and time-consuming problem, but the safety of a plant is diminished when vital components of a fire protection system are not operating at peak performance. Less obvious impediments, such as a line restriction, can also have harmful effects if not adequately addressed.  Diligent execution of simple, yet effective practices, such as venting pockets of air from the high points in the system can help ensure that fire protection systems are functioning at their optimal capability in the event of a fire.

Properly maintaining a fire protection system within a power generating or industrial processing facility involves diligent testing, inspection and maintenance practices that are performed at regular intervals.  The scope of these functions is quite broad, entailing a host of actions on a wide variety of equipment. Unfortunately the breadth of these testing and inspection tasks can often cause critical elements of a system, such as fire water supply, to be overshadowed.  Adequate fire water supply is essential to the operation of water-based fire protection systems, yet many facilities are not aware that their supply may be insufficient for optimal performance.

Why is Sufficient Fire Water Supply Important?

Fire water supply is the lifeblood of fire protection systems and when demand exceeds supply, the consequences can be disastrous.  Fire protection systems depend on a specific pressure and volume of water to control fires and when the supply is not sufficient, their effectiveness is compromised.

As supply becomes diminished, each demand item (e.g. monitor, hose stream, sprinkler system) becomes ineffective in direct proportion to the failing supply.  A supply shortage can be evidenced by lower pressures and reduced volumes discharged from the equipment.  Every piece of a fire protection system has a minimum water supply design specification and when that standard is not achieved, systems do not function at optimum capacity. 

Another more grave consequence of inadequate supply occurs when the water supply source runs dry.  For example, if a system demands 10,000 gallons per minute and the system’s fire water supply is 100,000 gallons, the system would run dry after only 10 minutes.  Most plants have a finite fire water supply and if the allocated amount is not substantial enough to distribute sufficient water to the fire protection systems for the designed amount of time, there is a possibility that fires will not be properly controlled, potentially causing considerable damage to the plant.  

How do Plants Become Deficient in Water Supply?

When the hydraulic design calculations for a fire protection system are performed for a specific facility, they are based upon the current configuration of the plant at that time.  Because the lifespan of most power generating facilities or industrial processing plants is several decades, it is likely that modifications will be made to the site plan of the plant to reflect fluctuations in production or expansion of the facility.  As this occurs, fire protection systems must also expand to correspond with the developing facility to remain in compliance with NFPA standards and insurance underwriters’ requirements. 

A growing fire protection system demands additional fire water supply but this aspect of system expansion is too often overlooked, putting the facility at risk that their fire protection system will not function as intended in the event of a fire. To perpetuate the issue, many facilities find themselves under multiple ownership histories, making it a strong possibility that the original design data has been lost.  Without the initial design information, it is difficult to make a valid determination about how much fire water supply is needed for systems to function properly.  When a plant cannot verify their supply versus their demand, it becomes necessary to conduct testing to establish whether or not modifications need to be made to increase a facility’s supply.

Methods for Determining Fire Water Supply

There are a few methods that are effective for determining if fire protection systems are receiving enough water for effective operation.  Each of these options has varying degrees of effort, usually with corresponding levels of accuracy.

Gradient Flow Test

Conducted to determine the volume of water available at any given location, gradient flow tests are more precise than any computer-modeling-based test because the data is collected from actual flow test results as opposed to theoretical assumptions.  Calibrated flow measurement devices are installed at appropriate test locations based on the hazard and system configuration.  Water is flowed through the devices at several increasing volumes and the residual pressure is recorded at the test point for each flow rate test.  The data is subsequently analyzed and plotted on a flow curve to provide visual results of flow volume in terms of gallons per minute at a specific pressure.

Fire Pump Performance Test  

Another technique for measuring fire water supply that is less intensive than gradient flow tests is a fire pump performance test.  These tests are performed to determine the volume of water that is produced by the fire pumps, which is an indicator of the facility’s fire water supply. 

Before beginning the test, the manufacturer’s pump ratings, such as gallons per minute (gpm), pressure (psi) and speed of the pump (rpm) must be determined.  The pump is tested on three points per NFPA 25:

1. Churn – No flow
2. Rated Flow – Flowed at 100%
3. Excess Capacity – Flowed at 150%

Factor Testing

To rule out the presence of an obstruction that is impeding the flow of water within an underground piping system, a factor test can be conducted.  In the event that an obstruction is present within the piping, it can result in excessive loss of volume, rendering the fire protection system ineffective. 

Factor test are conducted by using two points – a pressure measurement point and a flow point– that are typically established on a straight run of pipe.  The actual distance between the two points is recorded and water is subsequently flowed from the flow point.  After data is collected, it is analyzed and compared to the flow characteristics of normal pipe interiors to determine if there is a possible obstruction inhibiting the water flow.

Methods for Determining Fire Water Demand

Equally important, the fire water demand of a power generating plant or industrial processing facility must be calculated in relationship to the supply.  The various methodologies for acquiring this information depend upon not only the level of exactness that the facility requires but also the design information that is available to the personnel conducting the tests.

Hazard Classification

A process that involves taking a detailed inventory of the occupancy and material hazards of a facility, hazard classification surveys verify that the proper fire protection design criteria is being used.  Surveys of all handled and stored materials as well as the different structures and their occupancy are performed to determine the hazard classifications throughout the site.  Water supply demands can then be assessed based on the acquired data. These surveys are normally performed by someone well-versed in the applicable NFPA standards who has the expertise to formulate an accurate analysis.

Water Spray Systems Analysis

An alternative means for establishing water demand is through examination of each water spray system.  If they are available, the facility can utilize the original design prints and hydraulic calculations to determine if the fire water supply meets the demand of the fire protection system.  It is crucial to verify that if the system has been modified from its original form that the design and calculations that are being used in the water spray analysis correspond with the current design.

 In instances where the original design is not available or reflective of the current installation, the facility must undergo a reverse engineering process to gauge the fire water demand.  To begin, the existing pipe must be carefully surveyed and a set of as-built sketches created.  Once the sketches have been formed, they are converted into Auto-CAD drawings to create a set of hydraulic calculations.  This procedure is far more intensive than the former processes and requires highly skilled professionals who are experienced in fire protection system layout and design.

A Summary of Fire Water Supply vs. Demand

The issue of fire water supply was one that formerly was not a high priority for most power generating plants or industrial processing facilities.  However, this aspect of fire protection has recently become a point of focus for many insurance underwriters, which has consequently escalated its importance to facilities as well. 

Calculating the supply and demand of a fire protection system can be a complex, labor-intensive endeavor, which unfortunately deters many facilities from completing the process.  Many times, the tests that must be performed exceed the knowledge of plant staff and should be performed by qualified fire protection personnel to ensure accurate analyses.    

Beyond the requirements of insurance companies, fire water supply is a critical piece of the fire protection puzzle that is essential to the functionality of water-based systems.  Having accurate knowledge of the current supply versus demand should be a top concern for facilities that are committed to protecting their valuable assets.  When considering all of the time and investment that are spent on maintaining the functionality of fire protection systems, it must be remembered that without adequate water supply to meet the demand, systems may not perform to the degree that is necessary to sufficiently protect facilities.

With a background that includes a wide array of experience, Mr. Harding has been providing fire protection solutions to heavy industry facilities for 17 years.  He spent the first eleven years of his professional career working in a design/project management role where he was responsible for the design and calculations of various power plant fire suppression and detection systems as well as the management of multi-million dollar projects.  His experience included designing the full breadth of fire suppression and alarm/detection systems for every aspect of power generating plants, from turbine underfloors to conveyors.

 Mr. Harding received an AAS degree in Architectural Engineering from ITT Technical Institute and graduated from OSU’s Fire Protection and Safety Technology (FPST) program.  He is registered through the National Fire Protection Association (NFPA) as a Certified Fire Protection Specialist, is NICET Level III certified in Automatic Sprinkler Systems, and holds Member Grade status in the Society of Fire Protection Engineers (SFPE).  He is also active in the Industrial Fire Protection Section of NFPA. 

Brian Ramsey, President of F.E. Moran Special Hazard Systems, says: “As Gene’s successor, Brian is dedicated to providing his clients with the highest level of service and attention to perpetuate the tradition of delivering a premium product to our customers. The diversity of his experience within the industry provides Brian with consummate expertise and knowledge, giving him a comprehensive perspective of the process.”

F.E. Moran Special Hazard Systems provides fire protection solutions for heavy industry environments such as chemical and power plants.  Extensive knowledge of design methodologies and current codes along with consummate installation techniques provide customers with dependable turnkey solutions that satisfy their specific needs.  As an industry leader with over 30 years of experience, more than 700 high-risk facilities across the globe have trusted F.E. Moran Special Hazard Systems to implement and maintain flexible, reliable fire protection systems.

This video illustrates a deluge system that has an inoperative nozzle that is trickling water instead of projecting an effective, targeted blast.  This system, which protects one of the power generating plant’s valuable transformers, underwent a flow test, which subsequently revealed the malfunctioning nozzle. Had the system been triggered by an actual fire, the consequences could have been disastrous.

Regular internal pipe inspections are critical to ensuring sprinkler systems are not hindered by internal blockages.  Because of obstructions within the pipe, the bottom right nozzle of this deluge system is trickling water instead of projecting the spray pattern that is necessary to control volatile transformer fires.                          

Transformers are powerful, volatile pieces of equipment that require robust, effective fire suppression solutions to mitigate the risk of high-intensity fires.   Factors such as high voltage, large quantities of flammable transformer oil and the common presence of deteriorated insulation elevate the risk of fire, making it essential that sprinkler systems are operating at full capacity.  Any sprinkler equipment malfunction can result in failure to control a fire which can lead to catastrophic oil tank ruptures, and potential ignition of adjacent transformers.

Impediments like the ones highlighted in this video are often a result of blockages, which are caused by factors such as corrosion or debris within the pipe.  When deposits of debris such as corrosion nodules, rust and slime accumulate within a pipe, the diameter through which water can travel is reduced, constricting water flow.  As layers of deposit develop, the friction within the pipe increases, reducing the flow that is expelled from the system.  Another potential problem occurs when this debris travels to the sprinkler head and becomes lodged, inhibiting the spray or possibly blocking the flow completely. 

Unfortunately, because the problem originates internally within the pipe, these obstructions usually go undetected without proper inspection and testing.  In accordance with NFPA 25, an internal pipe inspection should be conducted every five years to identify the presence of potential obstructions.  These inspections can be complicated and require specialized equipment in order to be effective.  An internal pipe inspection should be conducted by a knowledgeable professional who can reveal these issues so that they can be rectified before a sprinkler system is needed to control a fire.

Another concern that must be considered when installing fire suppression systems for pumps is the placement of the nozzles.  Commonly, nozzles are positioned at an elevation that is too high and distant to be effective, rendering the suppression less effective. 

F.E. Moran Special Hazard Systems installed 42 deluge systems at the Hastings Extraction/Fractionation Plant in Pine Grove, WV, which included protection for the plant’s Drip Gasoline Reflux Pumps.   

The Hastings Extraction Plant is a natural gas processing facility that has a production of 180,000 MCF/day with fractionation up to 500,000 gallons/day.

F.E. Moran SHS Website

www.femoranshs.com, an information hub that offers fire protection resources for power generating plants and chemical processing facilities.  Tools such as inspection, testing and maintenance requirements, plant surveys and relevant fire protection articles are all readily available to visitors to the site.  The website also provides a secure portal in which client documentation is housed for instant accessibility.

Brian Ramsey, President of F.E. Moran Special Hazard Systems, says of the website: “As an industry leader that has amassed a vast collection of experience about highly specialized fire protection solutions over the past three decades, F.E. Moran has decided to proactively share ideas and information with industry personnel responsible for addressing fire protection challenges at their facilities.  The objective of this website is to provide plants with additional resources that can help them optimize the performance of their fire protection systems, subsequently enhancing safety within their facilities.”

In addition to the public domain, the F.E. Moran Special Hazard Systems website also offers a customer portal, which allows clients to log in to a secure site that stores an array of facility-specific documentation.  Inspection and testing reports, drawings and other pertinent fire protection system documentation is conveniently available at the facility’s fingertips, making it immediately accessible for local authorities, insurance representatives or corporate safety personnel.

When operators do not thoroughly understand how FACPs function and do not know how to appropriately respond to their signals, the consequences can be devastating. Few emergencies in a power generating plant are more threatening than a fire condition. Fortunately, this scenario can often be avoided by educating plant staff about how to properly utilize FACPs.

Identifying Panel Types

The first step in understanding the functionality of FACPs is identifying the type of system that is utilized in the facility. Today’s fire protection system control panels range from basic hardwired panels to the sophisticated addressable/intelligent type. Variables such as hazard type, age of the system and criteria required by the specifying engineer all influence the type of system that is employed.

Hardwired panels were the primary fire protection system controls up until the early to mid-80′s when addressable/intelligent fire alarm systems made their entrance into the market. Hardwired systems relied on panel mounted modules that terminated circuits from groups of similar devices, such as a cluster of heat detectors over a Lube Oil Reservoir, or pull stations located at the egress doors from a Tripper Floor. Additional circuits would then connect to the alarm signaling audible/visual device, sprinkler riser switches (waterflow, tamper, low air pressure) and releasing solenoid valves, if applicable.

Comparatively, addressable/intelligent systems utilize significantly less wiring by using Signaling Line Circuits (SLC). The SLC is the heart of the addressable/intelligent fire alarm system, communicating with all of the input devices such as intelligent smoke detectors, addressable pull stations and relays and signaling circuit control modules over a common pair of wires.

All of these panels perform the same basic functions, but over time the competitive nature of the market has resulted in the evolution of FACP’s capabilities with the introduction of new functions and features. Early FACPs performed basic functions such as: receiving alarm, trouble and supervisory signals; activating signaling circuits; energizing relays for equipment shutdown and closing fire doors. Addressable/intelligent systems have become markedly more powerful, capable of handling hundreds of devices, performing complicated functions through panel programming and providing system status via LCD screens.

It is common to find a sampling of different types of panels within a power generating plant. Because the panels may have been installed during different stages of time, it is not unusual to find everything from small hardwired FACPs to larger addressable/intelligent FACPs in the same facility.

Panel Locations

The most prevalent systems that are found within power generating plants are hardwired panels because addressable devices typically do not meet the NEMA 4, 4X or explosion-proof standards for resistance to environmental elements and corrosion. Standard intelligent devices such as smoke detectors or manual pull stations are ideal for installation in locations such as Control Rooms, DCS Rooms, Switchgear spaces and offices, but are not designed for the severe environments, temperatures, humidity and classified areas where a coal belt, turbine underfloor or transformer reside. These harsh environments require rugged devices designed to withstand extreme conditions, which are then wired to an interface module that is located in a controlled environment. It is possible that the interface module is located in the same area as the FACP, or it can be housed in separate area, requiring additional wiring to connect the interface module to the FACP. This means that it is possible to have a powerful, addressable/intelligent panel, but all of the wiring may still originate out of the panel as though it was a hardwired FACP.

How do FACPs Work?

The early hardwired FACPs relied on internal jumpers and relay logic to perform any functions outside of basic general alarm, trouble or supervisory signaling. Over time, relay logic technology has been replaced with onboard programming through proprietary software that is installed from the fire alarm technician’s personal computer. Using this software, the system can be manipulated to generate a specific reaction to various inputs. Latter generation hardwired FACPs incorporate microprocessor controls programmed through their keypads that incorporate basic logic programming, eliminating the need for relays and non-supervised internal interconnecting wiring.

 Interpreting Signals

In a typical day, an operator can encounter hundreds, or even thousands, of alarms in the power plant control room. The catalysts for these alarms vary in significance and it can be difficult to prioritize these alarms, especially if there is not an alarm management system in place. Deciphering FACP signals begins with understanding the basic Fire Alarm System messaging:

The FACP can be in any one or all four conditions simultaneously. In an ideal situation, only the green light will be illuminated, which means that there are no active alarms, system issues or supervisory signals on the panel. A yellow supervisory signal signifies an event such as an Outside Screw and Yoke (OS&Y) or Post Indicator Valve (PIV) that is in a closed position or a signal from a duct or gas detector. The other yellow light reveals system trouble and points to issues with the system’s operation such as problems with hardware, software or the wiring from panel to field devices. It is imperative that system trouble signals are investigated and rectified as fire alarm signals may not be received if equipment is malfunctioning. Red fire alarm signals are the most critical alarms as they denote a fire situation that requires immediate action.

In addition to these basic signals, higher-end addressable/intelligent FACPs can have more advanced indicators on the panel such as: annunciate security inputs, a Special Hazard discharge indicator, a pre-alarm signal indicator, indications for silenced signal circuits and more.

Each signal is distinct for obvious reasons and demands that it is addressed accordingly in a timely manner. Unfortunately, service teams often arrive at a jobsite to find a FACP in alarm, trouble or supervisory mode, with the panel having been silenced and ignored. FACP signals are designed to mitigate risk and effectively notify staff about emergencies. Disregarding these signals thwarts the effectiveness of the FACP and puts plant assets and lives at risk.

Why do FACP Signals Go Ignored?
The reasons that these vital signals are often disregarded are abundant but they range from inadequately trained personnel to cryptic messaging. At times other tasks take precedence over attending to FACP alarms because staff members do not fully understand the gravity of some of the signals. The unavailability of spare parts for the system can also result in perpetually active alarms. Other explanations include vague drawings, lack of cable tabs for the system wiring and incomplete or missing operation and maintenance manuals. Some plants even bypass a relay or circuit so that production is not temporarily interrupted.

Educating Plant Staff to Successfully Manage FACPs
FACPs are implemented as a measure of protection to inform operators of potential or impending risks. However, when plant staff is not thoroughly educated about the functionality and associated indications of FACPs, the systems are rendered ineffective. Plant owners rely on operators to accurately interpret these signals and take immediate action to prevent issues from escalating. When signals do not receive timely response or they are overlooked altogether, risk levels are elevated.

Putting a training program into practice is the best way to ensure that staff will understand proper protocol for various scenarios related to the FACP. A comprehensive curriculum should include areas such as: understanding hazards pertinent to the environment, identifying critical FACP components, FACP and valve operation and system programming. Whether staff simply need a review of FACP basics or in-depth instruction is necessary, having staff that is well-versed in these areas is a long-term investment. In the aftermath of a fire, it is too late to find out that a disaster could have been averted had plant staff fully understood the implications of an FACP signal.