Download - Guidelines Fire Protection Pirelli
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PIRELLI TYRE S.p.A.PROJECT: 13003
DOC.NO.: 13003-M-FF-00-RT-1000-TO
INDONESIA MOTO PLANTDATE: 04/04/2013
PAGE: 1 PAGE : 28
PIRELLI TYRE
Subang Moto Plant report design
GUIDELINE FOR DESIGNING A FIRE
PROTECTION SYSTEMS ACCORDING TO FM
GLOBAL SPECIFICATIONS
13003-M-FF-00-RT-1000-TO
TO 04/04/2013 Design for Tender PG IM AZ
REV. DATE DESCRIPTIONPAGES PREPARED
BY
CHECKED BY
AUTHORIZED BY
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INDEX
1 SCOPE OF THE DOCUMENT 3
2 DESCRIPTION OF THE AREAS TO BE PROTECTED 3
3 REFERENCE STANDARDS AND PROJECT DOCUMENTS 6
4 STRUCTURAL DESIGN SPECIFICATIONS 8
5 FIRE FIGHTING SYSTEMS DESIGN 9
5.1 SPRINKLER SYSTEMS DESIGN 9
5.2 HYDRANTS SYSTEMS DESIGN 16
5.3 WATER SUPPLY AND PUMP STATION SPECIFICATIONS 19
5.4 UNDERGROUND AND ABOVEGROUND MAINS 27
5.5 ALARMS SIGNALS AND MANAGEMENT 31
6 FLAMMABLE LIQUID STORAGE 32
7 SMOKE DETECTION SYSTEMS 32
8 HYDRAULIC CALCULATIONS 33
9 OTHER TOPICS TO IMPROVE 33
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1 SCOPE OF THE DOCUMENT
The scope of this report is to provide a guidel ine to better understand FM Global
standard s and on ly with t he a i m to prov ide t echn i ca l su gge st ion s fo r d e s i g n
i n g fire protection systems that will be installed to protect the new Pirelli tyre plant, located in
Subang (Indonesia).
This document defines the basic requirements to elaborate preliminary Fire Protection Systems.
Each information must be verified by contractor with reference to FM Global Standards. The
document only refer to FM global standards and don’t take into account the applicable Indonesia
Law.
All the specifications described in the following paragraphs are only indicative and reflect current
requirements, so they may be subject to changes / additions in the future and they must be
mandatory verified by contractor, in order to develop preliminary fire protection project design,
that must necessarily comply with FM Global standards, as requested.
2 DESCRIPTION OF THE AREAS TO BE PROTECTED
The new plant, dedicate to produce Moto tyre, is located at the Subang area in Jakarta region.
The plant cover a total area of about 51,000 m2 ,main building including officies, facilty, and
utilities building production.
Specifically, the spaces to be protected, inside the main building area, are the following:
Mixing room building 101;
Raw material warehouse building 101
Semifinishing building 102
Tyre building 103
Curing building 104
Finishing building 105
Warehouse building 106
Indoor test Building 107
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Internal Electrical secondary with transformers MV/LV
Internal room with UPS for officies
Fire pumping station room;
Offices, Laboratories, Toilets, Canteen, infirmary
M u s h o l l a
W a s t e Storage area
3 REFERENCE STANDARDS AND PROJECT DOCUMENTS
The fire protection systems project must be prepared according to Factory Mutual reference standards and specifically according to the following applicable standards (master standards but not exhaustive list):
FM data sheets 2-0 - INSTALLATION GUIDELINES FOR AUTOMATIC SPRINKLERS
FM data sheet 3-7 - FIRE PROTECTION PUMPS
FM data sheet 3-2 - WATER TANKS FOR FIRE PROTECTION
FM data sheet 3-0 – HYDRAULICS OF FIRE PROTECTION SYSTEMS
FM data sheet 5-48 – AUTOMATIC FIRE DETECTION
FM data sheet 8-9 – STORAGE OF CLASS 1, 2, 3, 4 AND PLASTIC COMMODITIES
FM data sheet 4-5 – PORTABLE EXTINGUISHERS
FM data sheet 5-40 – FIRE ALARM SYSTEMS
FM data sheet 5-18 – PROTECTION OF ELECTRICAL EQUIPMENT
FM data sheet 7-83 – DRAINAGE AND CONTAINMENT SYSTEMS FOR IGNITABLE LIQUIDS
FM data sheet 7-88 – FLAMMABLE LIQUID STORAGE TANKS
The basic project design include :
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13003 M FF 00 LI 0100 TO SPRINKLER LIST - PROCESS OCCUPANCIES
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13003 M FF 00 LI 0150 TO SPRINKLER LIST - OTHER ACTIVITY13003 M FF 00 LI 0125 TO SPRINKLER LIST - STORAGE13003 M FF 00 PI 8020 TO SPRINKLER SYSTEM FOR MAIN BUILDING - P&ID 13003 M FF 00 PI 8010 TO SPRINKLER SYSTEM UNDERGROUND PIPE - P&ID 13003 M FF 00 PI 8001 TO SPRINKLER SYSTEM FIRE STATION - P&ID 13003 M FF 00 DS 0100 TO FIRE STATION DATA SHEET13003 M FF 00 DS 0125 TO SPRINKLER SYSTEM DATA SHEET13003 M FF 00 DS 0150 TO HYDRANTS SYSTEM DATA SHEET13003 M FF 00 DS 0175 TO Valve list13003 M FF 00 RT 1000 TO FIRE FIGHTING REPORT13003 M FF 00 BQ 0010 TO FIRE FIGHTING BILL OF QUANTITY13003 M FF 00 GA 0100 TO FIRE FIGHTING GENERAL DISTRIBUTION LAYOUT13003 M FF 11 GA 0100 TO FF BLd 11 - Ground Floor13003 M FF 11 GA 0125 TO FF BLd 11 - First Floor13003 M FF 11 GA 0150 TO FF BLd 11 - Second Floor13003 M FF 12 GA 0100 TO FF BLd 1213003 M FF 13 GA 0100 TO FF BLd 1313003 M FF 14 GA 0100 TO FF BLd 1413003 M FF 15 GA 0100 TO FF BLd 1513003 M FF 21 GA 0100 TO FF BLd 21
13003 M FF 22 GA 0100 TOEQUIPMENTS LAYOUT - BUILDING 207 - FIRE FIGHTING TANKS AND PUMP STATION
13003 M FF 22 GA 0100 TO FF BLd 2213003 M FF 23 GA 0100 TO FF BLd 2313003 M FF 24 GA 0100 TO FF BLd 2413003 M FF 31 GA 0100 TO FF BLd 31 Ground floor13003 M FF 31 GA 0125 TO FF BLd 31 First floor13003 M FF 32 GA 0100 TO FF BLd 3213003 M FF 33 GA 0100 TO FF BLd 33 Ground floor13003 M FF 33 GA 0125 TO FF BLd 33 First floor13003 E FA 00 BD 0100 TO Fire Fighting - System Architecture Block Diagram13003 E FA 11 GA 0100 TO Fire Fighting - 101 Mixing room and Raw Material Warehouse13003 E FA 12 GA 0100 TO Fire Fighting - 102 Semifinishing13003 E FA 13 GA 0100 TO Fire Fighting - 103 Tyre Building13003 E FA 14 GA 0100 TO Fire Fighting - 104 Curing Building13003 E FA 15 GA 0100 TO Fire Fighting - 105 Finishing / 106 Finished PW13003 E FA 21 GA 0100 TO Fire Fighting - 201 Electric / 202 Water / 203 Air13003 E FA 22 GA 0100 TO Fire Fighting - 207 Fire Fighting Station13003 E FA 23 GA 0100 TO Fire Fighting - 204 Boiler House13003 E FA 24 GA 0100 TO Fire Fighting - 107 Indoor Test13003 E FA 31 GA 0100 TO Fire Fighting - 901 Office13003 E FA 32 GA 0100 TO Fire Fighting - 903 Infirmary / 904 Canteen / 905 Mosque13003 E FA 33 GA 0100 TO Fire Fighting - 906 Lockers Room13003 E FA 34 GA 0100 TO Fire Fighting - 907 Entrance13003 E FA 42 GA 0100 TO Fire Fighting - 402 Flammable Storage / 403 Oil Storage
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Particularly, to provide a correct hydraulic calculation document, it is necessary, in the final
project, to elaborate the details document .
Only after FM Global approval the firefighting systems project can be considered suitable.
All the necessary details and any changes required by FM Global must be incorporated
in the final project.
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4 STRUCTURAL AND CIVIL DESIGN SPECIFICATIONS
Following general rules shall be adopted into the detail structural and civil design:
- all the main construction materials used in the factory shall be not combustible materials (insulations, cladding panels, skylight, …)
- the fire rating (R180) and the intumescent painting shall be foreseen only for the following buildings: 101 Mixing Room, 101 R.M. Warehouse, 123 Factory spare parts WH, 106 F.P. Warehouse, 402 Flammable storage, 403 Oil Storage. All the other process and civil buildings could be simply painted.
- REI 180 walls shall be foreseen between different production area (for example between 102 and 103), but not between production areas and adjacent buildings (for example between 103 and 902-C)
- in the layout must be provided an adequate distance between water reserve tanks, pump station room and protected spaces.
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5 FIRE FIGHTING SYSTEMS DESIGN
5.1 SPRINKLER SYSTEMS DESIGN
As a general primary guideline, sprinkler heads must be installed and spaced in accordance with
FM Global standards, that refer to following principal factors:
1. building height;
2. building structure;
3. slope of the roof;
4. internal areas typology;
5. Flammable liquids/gas/solids quantities stored in the different areas.
The following are the preliminary sprinkler systems design specifications, to be considered as
general references, it must be necessarily verified and justified with hydraulic calculations during
the development of fire protection specifications:
Production building
Wet sprinkler protection must be designed to provide a minimum density of 25lpm/ m 2.
For detailed features of sprinkler system types for Production Area refer to document 13003-M-
FF-00-LI-0100.
Maximum distance allowed between sprinkler heads and building ceiling is 350mm. However, it is
recommended 100÷120 mm distance installation under the ceiling.
A 1900 lpm hose allowance must be included in the hydraulic calculations, and a duration of
1,5 hour must be considered.
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W ar e h o u s e/ st o r a ge are a :
For detailed features of sprinkler system types for Production Area refer to document 13003-M-FF-
00-LI-0125.
A 950 lpm hose allowance must be included in the hydraulic calculations, and a duration of 1,5
hour must be considered.
Maximum distance allowed between sprinkler heads and building ceiling is 425 mm.
The Quick Response sprinkler protection must be extended 4,5 meters over each side
warehouse border.
Office, Laboratories, Canteen :
For detailed features of sprinkler system types for Production Area refer to document 13003-M-FF-
00-LI-0150.
A 1900lpm hose allowance must be included in the hydraulic calculations, and a duration of 1,5
hour will be considered.
Utility room/Equipment room:
For detailed features of sprinkler system types for Production Area refer to document 13003-M-FF-
00-LI-0150.
A 1900lpm hose allowance must be included in the hydraulic calculations, and a duration of 1,5
hour will be considered.
Fi r e p u mpi n g sta t ion r o om :
This area must be protected by sprinkler system, according to FM Global specific standards.
Generally, the distance between sprinkler heads and building roof ranges from 25 mm to 300 mm
from intrados roof.
A reduction distance must be considered between perimetral sprinkler heads and perimetral walls
inside the building, in compliance with FM standards.
Sprinkler equipment must be realized in order to be tested at 14 bar for 4 hours, according to FM
Global standard. Test should be conducted on graphic printer that shows time and related pressure
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value.
Fire pumps must ensure an operating constant pressure of 12 bar for sprinkler equipment.
Small pressure fluctuations must be compensated by a jockey pump.
Flushing connections should be provided and connected from all sprinkler cross main ends. The
flushing connections should consist of a nipple sized at 50 mm or larger, an isolation valve and
extend to outside directly.
To feed sprinkler systems must be provided alarm check valves that are characterized by the
following main components:
1. Water motor alarm or electrical device alarm (to generate local alarm in case of sprinkler
system activation);
2. Flow meter (for carry over the remote alarm towards the control room);
3. Drain system piping (for sprinkler system discharge).
Below is attached a typical alarm check valve diagram. It shows a typical wet system riser.
Fig.1 – Example of Wet system riser
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It is also necessary to provide a single collector, on which all alarm check valves are installed and it
must have post indicator valves to section each portion of sprinkler protection system, controlled by
each single alarm check valve (N°1 Post indicator valve for each alarm check valve and N°1 Post
indicator valve on the water supply pipe):
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Fig. 2 – Example of Alarm check valves collector
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5.2 HYDRANT SYSTEMS DESIGN
All the plant must be internal and external covered/protected with both internal hoses and external
yard hydrants, minimum diameter DN100. Hydrants must be spaced according to local standards
and current laws.
External hydrants must be UNI70 typology, internal hydrants must be UNI45 typology.
It also must be provided an external Fire Brigade pump connection.
To show equipment typologies required, some photographs are attached below:
Fig. 3 – Example of UNI70 hydrant (external hydrant)
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Fig. 4 – Example of UNI45 hydrant (internal hydrant)
Fig. 5 – Example of external Fire Brigade pump connection
Yard hydrant should be able to provide 1900 l/min flow rate at the minimum residual pressure of
1,4 bar.
Because of there isn’t an outside interruptible water source (as a drinking water pipe), it is
necessary to connect hydrants mains to fire pumps station.
5.3 WATER SUPPLY AND PUMP STATION SPECIFICATIONS
In order to feed the proposed sprinkler and hydrants systems, the new water supply must consist of a new
an external tank, with a capacity of 1500 m3, from which two FM Approved multistage diesel driven fire
pumps (100% backup), plus a jockey pump, must take suction.
Fire pumps must be designed and installed according to FM standards and it must be defined their
characteristic functional curve, with flow and pressure data.
Diesel fuel fire pump tank must be located close to the pump, in the same room.
Diesel fuel fire pump tank must be realized and kept filled up in order to ensure 8 hours of
continuous operation of the fire fighting pump.
A flow testing facility should be provided for the fire pumps. This could be on a by-pass teeing off the
discharge flowing through a FM Approved flow meter and back into the tank.
The flow meter should be able to test up to 175% of pump’s rated capacity. A control valve should not be
installed within 10 pipe diameters of the flow meter inlet or within 5 pipe diameters of the outlet.
Size test outlets so they are capable of water flow of not less than 175% of the pump’s rated
capacity.
The pressure relief valve should be placed between the pump and the pump discharge check valve so it can
be readily removed for repairs without disturbing the piping.
The water reserve duration must be 120 min.
Particularly, it is suggests the external tank solution, due to the presence of a superficial
groundwater that complicates underground tank installation.
Below is shown a typical external tank with circular structure, FM Global approved and in
accordance with NFPA regulations:
Fig. 6–Fire fighting tank
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The external tank must be installed on suitable reinforced cement wrought and the tank must be
tested and approved by FM Global, in accordance with NFPA standards.
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5.4 UNDERGROUND AND ABOVEGROUND MAINS
An underground main pipe must be provided to feed fire protection systems. The same pipe must be provided, for sprinkler system and for hydrant system:
Sprinkler system, UNI70 and UNI45 hydrants system: one underground main, made by
HDPE pipe, NP16 bar, external diameter 315 mm, looped around the plant;
The control valves must be the following:
OUTSIDE SCREW AND GATE VALVE type for above ground pipes:
Fig. 7– Example of outside screw and gate valve
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Other general information:
Rubber flexible connection should not be installed on the fire protection piping and the fire
pump connections;
Inspector’s Test Connectors should be provided and connected from the most remote branch
line ends and should be directly extended to an open area outdoor without any “tundish” so
Carbon steel (black and galvanized) pipes thicknesses must be in accordance with FM DS
2-0, with minimum thickness 3,25 mm, for threaded joints, and 3,4 mm for cut-grooved joints.
Sub-horizontal trend pipes must have a minimum slope of 2 mm per meter towards drains system.
Branch lines, with a diameter larger than 2”, shall be connected by flexible joints, like Victaulic joints,
at least one every 6 meters.
Fig. 8 – Example of flexible joint
Pipes with diameter ≤ 2” shall be connected by joint screw and
sleeve. Where a pipe passes through a wall, it is necessary to provide
boat.
About the br anch line p i ping suppor t s , th ey must be in accordance with FM Glo b al s tandards a nd t he
m a x i m um d i stance between two co n secutive su p ports is 3,6 mt.
The maximum horizontal distance between supports and sprinkler heads is 0,3 mt.
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A typical FM approved support is the U-bolt typology support, used for main pipes (diameter ≥ 2”):
Fig. 9 – Example of U-Bolt support
Another typical FM approved support is the hanger typology support, used for smaller pipes (diameter <2”):
Fig. 10 – Example of hanger typology support
Pipes must be coated with a first rust proof paint layer (thickness 30 microns) and with two second enamel red colour layers RAL 3000 (thickness 25 microns per layer).
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5.5 ALARMS SIGNALS AND MANAGEMENT
All signals coming from firefighting systems must be relayed to a constantly attended location.
Particularly, signals of sprinkler water flow and fire pump start/stop, auto/manual and fail to start
should be sent to a constantly attended location.
Particularly, it must be provided an analogical detection/alarm central, that is connected with one or
more loops, in order to receive and handle the driving signals of sprinkler systems and smoke
detection devices and to transmit signals to the remote alarm monitoring station.
Finally, it must be provided also analogical alarm button and optical/acoustic alarm panel to
generate and display fire alarms.
Below are attached a photographs of these equipment:
Fig. 21 – Example of analogical alarm button
Fig. 22 – Example of analogical alarm button
The electrical cables of optical-acoustic panels, sprinkler flow switch, snooze and interlocks must be
realized with multi-type fire-resistant type FTG100M1 LSZH 2x2, 5 mm2.
The detection loop cables must be realized with multi-type fire-resistant type FTG100M1 LSZH , version 2x0,75.
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5.6 Inert Gas Fire Suppression System
The server room in building 902-C, shall be equipped with an Inert Gas Fire Suppression System. The
system typically consists of the agent, agent storage containers, agent release valves, fire detectors,
fire detection system (wiring control panel, actuation signaling), agent delivery piping, agent
dispersion nozzles, warnings and alarms (to avoid suffocation). These Agents are governed by the
NFPA Standard for Clean Agent Fire Extinguishing Systems - NFPA 2001 in the USA, or analogue in
Indonesia.
Fire suppression systems for server rooms and data centers are essential to the server room itself. A
fire suppression system will automatically extinguish a fire without the need of human intervention.
Fire suppression systems for data centers must be suitable for clean air environments, as server
rooms and data centers are mostly occupied by personnel.
This method is to reduce the oxygen level to below 15%. By reducing oxygen to this level it will
suppress a fire. The design must also consider the safety of personnel and keep oxygen levels to
above 12%, this will be sufficient to maintain life within an oxygen depleted environment.
Inert gas fire suppression systems will discharge its payload within 1 - 2 minutes
Will generally have more cylinders of chemical gases
Work with higher pressures, 200 Bar or 300 Bar
Will require Pressure relief venting
The designs standards for Fire suppression systems for server rooms and data centers are carried
out with strict guidelines, as the fire suppression agents used can be dangerous if not designed
correctly.
The design of the system must protects against accidental actuation due to any small leak. As a
general rule, extinguishing concentration is achieved when oxygen contents in the air is reduced from
its usual level of 20,9% to values lower than 15% depending on the combustible products.
6 FLAMMABLE LIQUID STORAGE
For flammable liquid storage the principal requirements are the following:
Mechanical low level ventilation; the mechanical ventilation project must be performed
following space classification of electrical system typology installed (ATEX);
Rated electrical equipment which should be suitable for hazardous environment;
Drainage and containment to prevent the flowing liquid into the area.
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7 SMOKE DETECTION SYSTEMS
Smoke and heat detection systems should be provided for all Electrical Rooms, Server Rooms,
office.
Air analysis unit for ceiling and floating floor detection systems should be provided for all
offices.
Transmitters infrared smoke detector and heat detectors should be provided for production
departments.
All detection systems shall be in accordance with local and current laws, including inside raised
floor area and other places where necessary. The signals should be transferred to a constantly
attended location, which could be the fire control center located in the guard house.
Detectors must be in accordance with EN54-7, with protection degree IP43.
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8 HYDRAULIC CALCULATIONS
On the basis of the above design specifications, a series of hydraulic calculations must be
provided. More in detail one calculation must be provided for each protected area.
In accordance with hydraulic calculation results, it will result specifications for fire pumps, with
a sufficient safety margin.
Considering a 120 minutes duration of the water reserve tank, it will result the water amount
needed to feed sprinkler system and hydrants system.
9 OTHER TOPICS TO IMPROVE
1. Fire and security signals;
2. Safety place points (emergency evacuation);
3. Valve padlocking and numbering;
4. Earthquake equipment and devices;
5. Fire extinguishers placement in the plant.