Fire Suppression Flooding System For Fire Protection GAIL VIJAIPUR Final
Fire Suppression Flooding System For Fire Protection GAIL VIJAIPUR Final
PROJECT REPORT ON
“Fire Suppression Flooding Systems for Fire
Protection: Detailed Applications and
Calculations for FM-200, CO2, and Inergen
Systems at GAIL VIJAIPUR Process Units”
AT
GAIL (INDIA) LIMITED
VIJAIPUR , GUNA (M.P)
SUBMITTED BY:-
1. ISHANA UKEY
2. ALOK DEEP
3. NAVEEN MAHLA
CERTIFICATE
D.G.M. (F&S)
GAIL (INDIA) LIMITED
VIJAIPUR, DIST. GUNA, MP.
(Mr. PRASHANT GIRIPUNJE)
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ACKNOWLEDGEMENT
I bow in reverence to the almighty for bestowing upon me the
opportunity and determination to embark on this study. Learning is
an active process hence perseverance to complete this task has been
a pleasing memory.
I express my sincere thanks to Mr. R.P.SINGH, G.M. (Fire & Safety) &
Mr. Prashant Giripunje, D.G.M(F&S) , GAIL (INDIA) LIMITED Vijaipur ,
for their precious direction .They have at all times been a source of
inspiration and knowledge for me.
INDEX
The GAIL India Limited, Vijaipur ,Guna district in the state of Madhya
Pradesh, is one of the biggest installations of GAIL India Limited, a
Public Sector Government of India Enterprises & Maharatna
Company. GAIL Vijaipur comprises of a Gas Processing (LPG Recovery)
Unit, Natural Gas compressor station and C2/C3 plant and 6” LPG line
to IOCL.
GAIL (India) Ltd., Vijaipur is one of the most strategic locations for
GAIL, being centrally located for the business of Gas transmission,
processing and marketing of Liquid Hydrocarbons. The company
commissioned in the year 1987 the nation’s first 2280 Km long cross
country trunk pipeline which was known as HVJ (Hazira-Vijaipur-
Jagdishpur) pipeline that had a gas transmission capacity of 18.2
MMSCMD for which GAIL Vijaipur was made the O&M (Operations &
Maintenance) headquarters. GAIL (India) Limited currently owns &
operates about 14,488 Km. of natural gas pipeline network with
approx. 75% of market share in Natural Gas Transmission within
country , connecting multiple gas sources to various customers .Since
then multiple major trans-state pipelines such as DVPL (Dahej-
Vijaipur Pipeline), VDPL (Vijaipur- Dadri Pipeline), GREP
Upgradation (Greater Rehabilitation Expansion Pipeline) & VKPL
(Vijaipur-Kota Pipeline) have been laid all with Vijaipur being
centrally located for continuous pipeline monitoring through Main Control
Room (MCR) at Vijaipur as well as day to day Pipeline O&Mactivities. This
MCR works in coordination with the National Gas Management Centre
(NGMC) at Noida (U.P.) for effective control & support for all pipelines
falling under the jurisdiction of Central
Region & therefor Vijaipur.
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PROCESS DESCRIPTION
The details of Major Facilities/Processing Units are given in table:
The dried gas is cooled to approx (-) 69 degree C in two stages. In the
first stage it is pre-cooled to approx (-) 39 degree C in chiller by heat
exchange with various cold streams generated later in the process in
the chill down system and external Propane refrigeration. Propane
refrigeration system is provided to supply additional refrigeration
required in chiller and LEF condenser for Propane recovery. The
condensed liquid is separated out in Separator-I and vapor is
expanded through a single stage Turbo-expander. The vapor-liquid
mixture from Turbo-expander is fed to Separator-II. The hydrocarbonliquid
from the two separators, after heat exchange, is fed to the fractionation
section to recover the products i.e. LPG, Propane,
Pentane and NAPHTHA. Vapors (Lean Natural Gas) from the second
separator are taken through the chiller to recover refrigeration. Then
it is compressed to about 30 Kg/cm2g by the expander compressor.
The quantity of lean gas required for NFL Plant & branch line of HVJ
pipeline is compressed in a GT driven two stage Lean Gas Compressor
to 45 Kg/cm2g (Medium Pressure Lean Gas) and the rest of gas is
compressed to 55.2 Kg/cm2g (High Pressure Lean Gas) and sent to
Vijaipur compressor station of HVJ pipeline for further transmission.
c. Distillation Section:
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and then send this sweet gas to Gas Processing unit for recovery of
C2/C3 product.
product forms the feedstock of Gas Cracker Unit at GAIL Pata plant.
Heavier product (propane and heavier) from GPU is sent to existingLPG
units phase I/II to produce Propane, LPG, Pentane & Naphtha. The lean
gas produced from C2/C3 recovery unit is sent back to existing HP/LP
Lean gas lines. Lean gas is also used as fuel gas in petrochemical
complex at Vijaipur.
Unit Capacity:
The GPU is designed to process total 21.72 MMSCMD mixed feed gas,
out of which 20.22 MMSCMD gas available from HVJ pipeline after
removal of CO2 in upstream Gas sweetening unit & 1.5 MMSCMD
RLNG gas from DVPL pipeline.
The rapid growth of business all over the world requires increasing
hydrocarbon transport capacity. A pipeline is actually a system of
equipment designed to allow material to flow continuously or
intermittently from one location to another.
GAIL operates approximately 11000 KM buried onshore Natural Gas
pipeline and around 2000 KM of exclusive LPG pipelines in India. The
Natural Gas pipeline network includes following cross country
pipelines viz. HVJ & GREP (Hazira-Vijaipur-Jagdishpur and Gas
Rehabilitation & Expansion Project) and DVPL-II (Dabej-Vijaipur
Pipeline) and VDPL (Vijaipur-Dadri P/L), DUPL-DPPL (Dahej Panvel
Dabhol Pipeline) & DBPL (Dabhol-Bengaluru Pipeline) and other
regional pipelines spread over western, southernand
eastern regions of India.
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GAIL has five Gas Processing plants situated at five different locations
of the country for recovery of value added fractions from natural gas
such as LPG. Propane, Pentane, and Naphtha. Five such plants are
located HVJ at Vaghodia, Gandhar, Usar, Vijaipur (02 units) & Auraiya.
In addition, GAIL is having one integrated Petrochemical Complex en-
route HVJ pipeline at Pata, Uttar Pradesh-Further C2C3 recovery plant
has been installed at Vijaipur.
The Major installations of GAIL are as under:
LOADING PROCEDURE:
Portability / plug-and-play
Every Cryobox module has the size of a 40 feet sea container, which
facilitates its delivery in a single trailer and multiple relocations in
reduced footprint plant areas.
The installation requires only concrete pads for its erection and
connection to gas sources, electricity services, compressed air and
internet.
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Proprietary technology
Its multi-stage liquefaction cycle eliminates possible inert contents
and is powered by a 450 kW motor connected to a MX 400 Galileo
Compressor.
Boil-off free
The automatic boil-off recovery system provides emission-free LNG
storage and loading. This feature avoids natural gas waste, ensuring
safe operations in compliance with environmental regulations.
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High availability
The minimization of dynamic components, use of fluids and labor
ensure an autonomous operation rate over 99%. This is especially
important for the operation in remote areas, such as hydrocarbon
fields.
24/7 monitoring
The operation runs entirely unmanned and includes a 24/7 remote
monitoring through Galileo Technologies SCADA System.
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PERFORMANCE EVALUATION
OF CO2 FLOODING SYSTEM OF
PRU COMPRESSOR IN LPG UNIT
INTRODUCTION
Carbon dioxide is a gaseous fire protection agent, also known by
its chemical equation CO₂, one molecule of carbon and two
molecules of oxygen. Normally, the air we breathe contains 21%
oxygen, 79% nitrogen, and only a trace amount of carbon dioxide,
0.03%. The presence of significantly higher percentages of carbon
dioxide in a room cannot be
Although these properties of carbon dioxide, combined with its
property of being incapable of conducting or transmitting electrical
charges, make it useful for protecting many items of equipment,
they also create a scenario for a potential hazard to human life when
high volumes of carbon dioxide are injected into a room. A CO₂
flooding system is a type of fire suppression system that uses
carbon dioxide (CO₂) to extinguish fires. CO₂ systems are
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ADVANTAGES
Density is 1.5 times higher than air. So CO2 settles down
anddisplaces air.
It can be easily liquefied and bottled.
20% – 30% CO2 concentration extinguishes
fire bysmothering
Non-corrosive
Non- conductor of electricity
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DISADVANTAGES
APPLICATIONS
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Primary Cylinder:
During a fire, on commencement of manual release switch, the valve of the
primary cylinder opens up to discharge the suppression agent. It is also
called 'Pilot Cylinder' as it is the first one to actuate and operate.
Slave Cylinder:
After the actuation of Primary Cylinder, the valves of these cylinders are
too actuated with the help of a pilot line so that they ensure continuous
supply of suppression agent.
If fire condition occurs it is detected by the Gas Release Panel through the detection
system. After implementation of logic and time delay, the panel will give 24V DC supply
to Master Valve solenoid. When the CO₂ master cylinder valve is opened, pressurized
CO2 gas will flow to the manifold through the high-pressure hoses, NRV. Part of the gas
quantity will be diverted from the Manifold and flows through hoses to actuate the slave
cylinder valves. Then pressurized CO2 will be discharged through discharge nozzles for
oneminute duration. Pressure Switch is fixed on the manifold, which shall sense CO2
Discharge & In turn, gives "Gas Discharged" signal to the Gas Release Panel.
There are total 8 compressor present in HVJ Compressor Unit Out of this 5 are main line
and 3 are branch lines compressor. Each compressor is protected by CO2 flooding
systems with 2 Cylinder of 45 kg and the system is operated automatically and manually.
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CHARGE WEIGHT – 45 Kg
Given:
Length: - 6.45m
Width:- 2.6m
Height :- 2.5m
Volume factor :- 1.01 Kg CO2/m3
Conversion factor :- 1
= 42.34425 Kg
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CONCLUSION :-
The theoretical calculation of CO2 flooding systems is lesser than the Actual Calculation.So, The
capacity of present cylinders is more than required quantity. Therefore, the capacity of cylinders
is sufficient to extinguish the fire in any scenario.
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Working:
If fire occurs in any of the protected GT enclosure of the unit, the solenoidvalves
located on the master cylinder of the initial discharge bank will get
energized by the electrical signal from the detectors and in turn through thefire
protection system control panel.
From The Control Panel, the signal shall be sent to the solenoid valve of the
initial discharge main cylinder battery assembly. The solenoid will be Energized,
thereby opening the cylinder valve and FM 200 pressure is applied to the
cylinder discharge heads. The FM 200 gas will pass through the flexible hosesto
the initial cylinder manifold, piping and to the FM 200 nozzles to the protected
area. If signal is not generated by the pressure switch fitted in theinitial cylinder
bank within short time interval, the solenoid valve of the standby cylinder will
be energized automatically through the fire protection
control Panel. In the same way, after time delay, solenoid of the master cylinder
valve fitted in the extended cylinder bank will be energized and causing the
cylinder valve to open.
With the master valve, discharge of FM 200 passes the flexible hoses to the
cylinder via manifold, piping and to the FM 200 nozzles to the protected area.
Pressure switch fitted in the initial and extended cylinder bank shall send the gas
discharge.
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Designing:
The design of the system consists of selection and proper placement
of the following equipment: Containers, Mounting brackets, Nozzles,
Pipe and fittings, Control panels, Detection, Optional accessories.
Step 1 – Agent Requirement: The first step in designing an FM-200
total flooding system is to determine agent weight requirements for
the desired concentration in the area(s) protected. To determine the
agent required for any space for a specific concentration, the volume
of the area must be known. Volume is defined as the capacity of an
area and can be found by multiplying its length x its width x its height.
Volume = (L x W x H).
The amount of FM-200 required to achieve the design concentrationat
a specific temperature can be calculated from the following
formula:
Step 4 – Nozzle determination: The nozzles are designed for 180° and
360° coverage. The nozzle should be placed as close or near to the
containers as possible to minimize system piping. The ceiling tiles
around each nozzle must be clipped to hold them in place during a
discharge and prevent damage. The orifices of the nozzles should not
be positioned to discharge on nearby objects. The maximum area of
coverage for a single nozzle in an underfloor is likewise 1,412 ft sq.
(131.2 m sq.)
Step 5 – Nozzle location: The nozzles may be positioned flush with the
ceiling or within 9.25 inch (23.5 cm) of the ceiling with the designradius
covering the required area.
RECOMMENDED ACCEPTABLE
CALCULATION:
e
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96 8
Therefore, W = *( )
0.1728 100−8
8
= 555.55 * ( )
92
= 48.31 Kgs
As, the total amount of FM-200 required for 8% Volumetric Conc. is
48.31 Kgs.
48.31 𝐾𝑔𝑠
Total no. of Main Cylinders= = 1 Cylinder
48.3 𝐾𝑔𝑠
BATTERY DESIGN:
RECOMMENDATION:
For a FM-200 cylinder of 46 ltrs water capacity, the suppressant
storage capacity is 48.3 Kgs.
And considering leakage losses and pressure losses in the cylinder, 1
cylinder of 48.3 kgs with 100% standby must be installed.
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ACTUAL DESIGN:
CONCLUSION :
NOTE: The extended delay cylinder is installed in addition to the
standby to increase the containment time and increase burn back
resistance thus making the system more effective
But, cost can be saved by considering sufficient less no. of cylinders.
Why IG 541 ?
Inert Gas IG 541 fire suppression system advantages :
• Environmentally acceptable.
• Colourless and odourless.
• Leaves no residue in occupied spaces.
• Electrically non conductive.
WORKING:
AUTOMATIC RELEASE :
1. The Automatic release is accomplished via detectors installed in
the protected area (detectors are Installed on cross Zone
principle to avoid accidental release of gas due to
malfunctioning / false Alarm). 2 As soon as a fire is detected by
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the two adjacent detectors, the fire signal from the fire Alarm
panel is sent to Gas Release Panel.
2. At the same time signal is provided to pre-discharge(Audio)
signal unit from the panel to allow personnel evacuation prior
to discharge.
3. Normally After a specified time delay (set time of 120 sec.) the
solenoid valve located on the master “IG 541” cylinder valve
assembly gets energised.
4. Simultaneously, respective solenoid valve/s Provided for the
selector/directional valve/s gets energised through Panel to
open directional Valve pneumatically, so that gas released from
cylinder bank can be directed to the hazard under Fire.
Installed In:
Following areas are covered under protection by Inertech System
1. Management Control Centre
2. HVJ Electrical Sub Station
3. DVPL Electrical Sub Station
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Where,
M= total flooding quantity, in kg;
C= design concentration, percent by volume;
V= net volume of the hazard, in m^3
S= K1 + K2 (T), where K1 and K2 are constants specific to the agent used and T is
minimum temperature inside enclosure;
Vs= specific volume of superheated agent at 21 C, in m^3/kg
Specific volume constants for IG 541 gas are K1 = 0.658 and K2 = 0.00239. Itmay
also be noted that this equation provides an allowance for the normal leakage
from a tight enclosure.
(b) The agent requirement per unit volume of protected space can also be
calculated by using the Table 11 for various levels of concentration
corresponding to the temperature within the protected enclosure.
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b. Battery Room.
Room Void = 980.4 m3
Total Volume = 980.4 m3
Design Concentration = 38.5%
Ambient Temp = 21oC
Vs = 0.708 m3/kg
Using this data in this above-mentioned formula the total flooding quantity of IG-541in
kg is
M= 476.53 kg
The Capacity of each cylinder is 58.625 kg
The total No. of main cylinders to be installed = 476.53/58.625
= 8.12
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= 9 Cylinders
Considering 100% Standby i.e. = 9 Cylinders for standby
Therefore, the total No. of IG-541 Cylinders required for switch gear room = 18
Cylinders
As, the no. of cylinders required for switch gear room are more than that of
battery room so, the number of main cylinders for the entire substation will be
equivalent to the number of cylinders required for switch gear room.
Therefore, No. of Main Cylinders = 20
No. of Standby Cylinders =
20 Total No. of Cylinders =
40
Total Amount of IG-541 = 40*58.625
= 2345 kg
Conclusion
Hence, the present quantity of IG-541 suppressant present at the VDPLSubstation
i.e 3283 kg is more than that required according to IS-15501 i.e 2345kg.
This excess quantity is a result of considerations of certain ventilations and cable
openings and other automatic closure failure cases.
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IG-55 is one of the most popular fire extinguishing systems due to the
extinguishing efficiency of its mixture of agents. It is suitable for
protecting hazards when there may be people in the enclosure at the
time of fire. It enables a safe evacuation, both in terms of the level of
oxygen in the room and the visibility required for the evacuation of
personnel, as well as ensuring the absence of chemicals in the
discharge.
This agent reduces the oxygen concentration to extinguish the fire,
but to a percentage suitable for occupied areas. The 50-50 mixture of
Argon and Nitrogen allows the perfect distribution of the agent in the
room for effective extinguishment.
It is highly recommended for class A, B and C hazards. The system
operates by total flooding of the room, ensuring complete discharge
in less than 1 minute.
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Gas Specification.
The gas specification is usually confirmed with a certificate of
conformity (COC) from the manufacturer. It’s also important to ensure
each specification is maintained during the 10-year testing and a new
COC is provided confirming each requirement below by your supplier
for the new re-filled or re-tested agent.
TheoreticalCalculation for
amount of IG- 55 Present at
MCR Building according to
IS-15506
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M = 1094.373 Kg
The capacity of each cylinder is = 32.1 Kg
The total No. of main cylinders to be installed = 1094.373/32.1
=34.09 ~ 35 cylinders
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2) RACK ROOM
Total Volume=2244.507 m3
Design concentration=37.9
Ambient temprature=21oC
Specific volume(Vs)=0.710514 at 21oC
Using the below mentioned formula, we get
M = 1069.35 Kg
The capacity of each cylinder is = 32.1 Kg
The total No. of main cylinders to be installed = 1069.35/32.1
=33.31~ 34 cylinders
Considering 100% standby i.e. = 34 cylinders standby
Therefore the total number of IG-55 cylinders required
for RACK ROOM=68 Cylinders
3) UPS ROOM
Total Volume=520 m3
Design concentration=37.9
Ambient temprature=21oC
Specific volume(Vs)=0.710514 at 21oC
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M = 247.491 Kg
The capacity of each cylinder is = 32.1 Kg
The total No. of main cylinders to be installed = 247.491/32.1
=7.71~ 8 cylinders
Considering 100% standby i.e. = 8 cylinders standby
Therefore the total number of IG-55 cylinders required
for UPS Room=16 Cylinders
4) BATTERY ROOM
Total Volume=300 m3
Design concentration=37.9
Ambient temprature=21oC
Specific volume(Vs)=0.710514 at 21oC
Using the below mentioned formula, we get
M = 142.845 Kg
The capacity of each cylinder is = 32.1 Kg
The total No. of main cylinders to be installed = 142.845/32.1
=4.45~ 5 cylinders
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MODE OF OPERATION
AUTOMATIC MANUAL
1)MCP
2)EPB
3)MANUAL LEVER
4)MANUAL ACTUATOR
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How it works?
Nitrogen/IG 100 systems are total flooding gaseous
extinguishing systems consisting of a fixed supply of the gas
within pressurised cylinders (200 bar and/or 300 bar) connected
to a piping system with nozzles located in accordance with
design manuals to direct the agent into a protected enclosure
(floor/room/ceiling void spaces). The systems can be manually
operated, but are usually operated via a fire detection system.
It is an invisible clear gas ensuring a safe and visually unobscured
exit from the affected area if discharged accidentally. In a fire
situation the discharge will mix the smoke to all levels of the
compartment, and this needs to be carefully considered in the
operating protocols.
Gaseous systems are ‘extinguishing systems’ only. Suppression
without extinguishment is a failed design.
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REFERENCES
NFPA:2001 (FM-200)
IS-15501 (IG-541)
IS-15506 (IG-55)
IS-15525 (IG-100)