G-10. Fire Fighting System Part-2 (Black & White)

PAITON Ⅲ EXPANSION PROJECT
COURSE – G (BOP)
CONTENTS ： G-10 Fire Fighting System

(Part-2)
TRAINER: Iskandar Syah (MINIMAX)
Hirokazu Miyazaki (PISCO JANAPN)
MITSUBISHI HEAVY INDUSTRIES, LTD.

NAGASAKI SHIPYARD & MACHINARY WORKS
G-10 FIRE FIGHTING SYSTEM TRAINING (O&M) PAGE- 2
OPERATION
&
MAINTENANCE
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Operation & Control
• Introduction
• Fire Water System
• Fire Pump Control
• Fire Detection & Alarm System
• Automatic Fire Control System
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OPERATION & CONTROL

Introduction:
• Fire detection and fire alarm systems are provided to protect the plant and
buildings against the fire hazards for all buildings, structures and areas on
the site.
• Fire protection systems involve the discharge of water, foam, fire fighting
clean agent gas and dry chemicals to suppress a fire.
• The type of suppression medium are selected according to the type of fire,
the expected size of fire and the equipment that is involved with the fire.
• Fresh fire water is provided from service water tank for normal operation of
the fire fighting system. Sufficient quantity of water is stored to fight a fire
at the largest fire risk for up to two hours.
• In the event that the service water system is unavailable then seawater will
be supplied from the seawater intake structure.
• Water will discharge from permanent automatic fire protection systems,
which includes deluge spray, pre-action sprays and wet pipe sprinkler
systems. The discharge rate of water from these systems will relate to the
anticipated size of fire at the risk source.
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Introduction (cont’d):
• Water will also be supplied from manually operated outdoor hydrants and
indoor hose stations for local fire fighting near to the hydrant or hose
station.
• Clean agent gas (FM-200) will be supplied by permanent gas suppression
systems for the fighting of fires in rooms containing key electronic
equipment.
• Carbon dioxide (CO2) gas will be supplied by manual operation from a tank
for interting in the coal silos in case of fire.
• Foam will be supplied for fighting against a fire in and around No.2 Oil
storage tank. The foam will be generated by mixing a small volume of
foam concentrate and a high volume of water.
• Dry chemical and carbon dioxide will be used in portable fire extinguishers
that will be used for the fighting of initial or small fires.
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Operation & Control
• Introduction
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OPERATION & CONTROL

Fire Water System:
• Fresh fire water for the plant is supplied from service water tank located
near the fire pump station.
• There are two (2) x 50% electric motor driven pumps and one (1) jockey
pump which maintains the fire water pressure in the piping system when
the main pumps are not in use.
• One (1) electric motor driven booster fire pump is provided in piping
system of boiler area to supply the fire water to indoor hydrants in boiler
area to get discharge pressure as required by NFPA.
• When a fire occurs water will be released from the fire protection system in
the fire hazard area.
• The pressure in the piping system will consequently decrease and the
main fire water pumps will start sequentially to meet the water flow rate
demand.
• As a backup supply of fire water, under extreme emergency, will be
provided by one (1) x 100% seawater diesel driven fire pump in the
seawater intake area.
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Fire Water System:
• The fire fighting water is supplied by the pumps to ring mains installed
around the plant areas and extended to coal handling system areas.
• Water for the fixed fire protection systems is supplied from this ring main.
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OPERATION & CONTROL

Fire Water Supply System:
• Maximum fire water requirement
The fire water supply system is designed to supply the fire water at the
maximum flow rate for the largest fire in the plant based upon the following
consideration.
a) Fixed water spray system for generator step-up transformer
: 10,790 Iit./min
b) Simultaneous operation of one outdoor hydrant
: 1,893 lit./min
Maximum water requirement = a) + b)
: 12,683 lit/min (3,355 GPM)
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OPERATION & CONTROL

Fire Water Supply System:
• Fire Water Pump Capacity
Pump Name Quantity Type Capacity Diff. Head
Motor Driven Horizontal, 2000 GPM

Two(2) 115m
Fire Water Pump Centrifugal (454.2 m3/h)
Diesel Engine Driven Vertical 4000 GPM

One(1) 115m
Fire Water Pump Turbine (908.4 m3/h)
Vertical, 32.4 GPM

Jockey Pump One(1) 115m
Centrifugal (7.2 m3/h)
Motor Driven Booster Horizontal, 158 GPM

One(1) 30 m
Fire Pump Centrifugal 120 m3/h)
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Operation & Control
• Introduction
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OPERATION & CONTROL

Fire Pump Control:
• The motor driven fire pumps, diesel engine driven fire pump, jockey pump
and motor driven booster fire pump are equipped with local controller to
start and stop the pumps, and to monitor the operating conditions.
• Motor driven fire pumps will start automatically when the ring main
pressure drops exceedingly by the fire fighting system operation, however,
these pumps are stopped manually at the discretion of responsible person.
• Jockey pump will start automatically and stopped to maintain the pressure
within the pre-determined range of pressure switch on the ring main.
• Seawater diesel driven fire pump will start automatically in case the fire
water cannot be supplied by the motor driven fire pumps from the service
water tank.
• Motor driven booster fire pump will start automatically when the standpipe
for the boiler area pressure drops exceedingly by the fire fighting system
operation, however, these pumps are stopped manually at the discretion of
responsible person.
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OPERATION & CONTROL

Fire Pump Control: (Outline of fire pump operation)
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Operation & Control
• Introduction
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OPERATION & CONTROL

Fire Detection & Alarm System:
• Fire detection and alarm system are divided into zones, and are provided
in buildings, structures and areas where there is a risk of fire.
• The alarm system will enhance the safety of personnel by providing early
detection and warning of a fire and provide time to escape from the fire risk
area.
• Alarms will identify the fire area and fire fighting resources will be directed
to that area.
• Alarms will reduce possible plant, equipment, systems and building
damage by reducing the delay between the time of ignition and the start of
effective fire fighting action.
• A fire detection system will initiate an alarm and automatic actuation of the
fire suppression system, where provided, on detection of fire.
• Detectors associated with the automatic fire suppression system will
actuate the fire suppression system and detectors associated with the
alarm system will initiate the fire alarm on detection of fire.
• Manual call point stations will also be provided to initiate fire alarm.
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OPERATION & CONTROL

Fire Alarm System:
• The fire alarm system is based on an addressable concept for the multiple
network annunciation panel (Main Fire Alarm Panel - MFAP) and Local
Fire Alarm Panels (LFAP)
• The basic concept for building fire alarm systems is to have a number of
local fire alarm panels, strategically located throughout the site; these are
of the addressable type.
• The fire alarm system consists of fire alarm panels, raceways, cables,
wiring, components and associated 24 VDC power supply systems, fire
suppression systems such as;
Sprinkler, Pre-action spray, Deluge, Gaseous fire suppression &
inertization system (FM-200 and CO2) and Alarm system components.
• Power to MFAP and LFAP are supplied from 120 VAC, 50 Hz, single
phase power source, and all fire alarm panels have a battery back up of 24
hours and all notification devices in alarm condition for 10 min.
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OPERATION & CONTROL

Fire Alarm System (cont’d):
• MFAP is installed in the central control room in the turbine building. Each
LFAP is connected as a network node onto the MFAP and provides
supervision of the systems such as fire alarm, trouble alarm, operation
status of fire pumps and fixed fire fighting systems.
• LFAPs are located geographically around the site in the main and auxiliary
buildings to provide the basic network. Each of the local fire alarm panels
sends information around the loop and provides all fire alarm and trouble
status signals to MFAP.
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OPERATION & CONTROL

Signal interface with other systems
1. VAC system
LFAP in each building sends zone fire signals to trip the air conditioning
system through the relay modules on the SLC (signal line circuit) loop.
2. Smoke fire dampers
When a fire is detected in a building or at the first detection of a fire on
FM200 system, LFAP outputs a damper close command through the
relay modules on the SLC loop and associated relays to shut all the
smoke dampers. The status of the dampers is monitored by the VAC
system control panels.
3. Fire pumps controls
All interface signals between the MFAP and fire pump panels are
ordinary Dry form-C contact signals provided through the addressable
control module on SLC of LFAP located in Desal. and Demi. Plant
building. Pumps start/stop functions will be provided on local pump
controller only. Main fire pumps can be started from MFAP manually.
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Signal interface with other systems
4. Radiator fans & oil pumps shutdown for transformers
When a high temperature is detected above the transformer, the
transformer will be de-energized prior to the fire water being released.
5. Miscellaneous equipment
Elevator, coal conveyor, etc. will be shut down by the fire alarm signal, if
necessary.
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Automatic fire detectors
1. Smoke detectors - Photoelectric smoke detectors, addressable, are used
for all normal location, connected to the SLC of the LFAP.
2. Heat detectors - Rate of rise heat detectors (Fixed temperature detectors
and Line type (linear) heat detector), addressable, are used for the
location where the smoke detectors may not be installed due to high
temperature, high humidity or dusty atmosphere.
3. Pressure switches - A pressure switch installed on the sprinkler, pre-
action spray and deluge valve set and FM-200 discharge line is
connected to the SLC of LFAP.
Manual call point station
This is a manual initiating and addressed ID codes device. Afire alarm
signal initiated by this device is transmitted to the LFAP through the SLC
loop.
This manual call point station is mounted at height not less than 1.1 m
and not more than 1.37 m above floor level.
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OPERATION & CONTROL

Notification alarm devices (audible and visible alarms)
• The notification alarm devices such as a fire alarm bell, alarm horn,
strobe light and alarm flash horn are conventional devices, two wires,
Class B and a separated power supply is required to operate these
devices when wired on the SLC loop.
1. Alarm bells
This is a conventional device with 24 VDC power source supplied from a
LFAP, and the bell is initiated by LFAP.
2. Alarm horn with strobe
This is a conventional device with 24 VDC operated, installed in high
ambient noise areas such as in turbine building and boiler area.
3. Alarm horn with strobe(FM-200)
This is a a conventional device, 24 VDC operated, installed inside and
outside of the rooms protected by FM-200 system for evacuation and
personnel safety.
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Operation & Control
• Introduction
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OPERATION & CONTROL

Control of Automatic Fire Fighting System:
1. Deluge system
Wet pilot deluge valves are installed for protection of transformers, main
oil unit and seal oil unit.
When a fire is detected by quartzoid bulb(s) and broken to open on the
wet pilot trim piping, deluge valve will be hydraulically opened.
Pressure switch on the trim piping will transmit a signal to LFAP for
operation alarm and water motor gong will produce piercing alarm locally.
2. Sprinkler system
Wet pipe sprinkler system is provided for the protection of turbine
operating floors, laboratory, etc.
Alarm check valves are installed for this sprinkler system. Resulting from
the discharge of water through one or more fused sprinkler nozzles at a
fire, the alarm check valve will be hydraulically opened to discharge water
on the fire.
operation alarm and water motor gong will produce piercing alarm locally
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OPERATION & CONTROL

Control of Automatic Fire Fighting System (cont’d):
3. Pre-action deluge system
Pre-action deluge system is provided for the fire suppression of
turbine/generator bearings and turbine operated boiler feed pumps which
provides the maximum protection from inadvertent water discharge to the
hot surface of the equipment.
To allow water flow to the system, two events must take place. Fire
detection by heat detector(s) must operate and the low pressure must be
operated by the loss of system air pressure (sprinkler operation).
These two signals must co-exist at LFAP which only then energize the
solenoid valve to release the water to the protected area.
operation alarm and water motor gong will produce piercing alarm locally.
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OPERATION & CONTROL

4. FM-200 system
FM-200 gaseous fire suppression system is provided for central control
room and control equipment room in turbine building and controlled by
LFAP using double detection sequence to avoid a possible mal-function.
The double detection sequence is initiated by a fire alarm signal coming
from the designated smoke detectors.
The first knock action initiated by a fire alarm from one of smoke
detectors will operate fire alarm bell in the protected room for personnel
evacuation. And VAC system will be stopped and smoke fire dampers will
be closed automatically.
As the second detection action initiated by a second fire alarm coming
from the smoke detectors, the alarm horn for the final evacuation sounds
for 30 seconds nor to FM200 gas discharge.
Selector valves within the discharge pipeline will be opened by a signal
from the LFAP in order to let FM200 gas to be discharged into the
concerned room.
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4. FM-200 system
When the FM200 gas agent is discharged after the above set time, the
alarm horn/strobe installed at the entrance to the protected room is
activated to prevent any entrance.
The manual release/abort switches installed at the operable location has
the abort switch to abort the FM200 gas discharging sequence.
The FM200 gas agent will be discharged within 10 seconds per
manufacturer’s standard design.
The FM200 cylinders are located at the floor above the protected rooms.
A selector switch is provided at the FM200 cylinders to select the cylinder
as ‘Main” or ‘Reserve’ so that the discharge from the reserve cylinders
can be activated after Main cylinders are used.
In the extreme emergency case, manual actuator valve on the FM200
cylinders can be operated to release FM200 gas into the protected room.
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OPERATION & CONTROL

5. Low pressure carbon dioxide (CO2) system
Carbon dioxide (CO2) system is provided for inert gas system for coal
silos, operated local-manually.
Operation and alarm signals from the control panel on the low pressure
CO2 storage tank will be indicated on LFAP and MFAP.
6. Foam system
Foam system provided for fuel oil storage tank is local-manually operated.
Operation alarm will be transmitted from pressure switch on the foam
discharge line to a LFAP and MFAP.
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Maintenance & Troubleshooting
• Fire Water Pumps & Motors

• Fire Water Pump Diesel Engine
• Water Spray Deluge System
• Sprinkler System
• Indoor & Outdoor Fire Hydrant System
• Foam System
• CO2 System
• FM-200 System
• Portable Fire Extinguishers
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CONFIDENTIAL
MAINTENANCE & TROUBLESHOOTING

MOTOR DRIVEN FIRE WATER PUMP (HORIZONTAL TYPE):
AH Type Pump Cross Sectional Drawing
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MOTOR DRIVEN BOOSTER FIRE WATER PUMP (HORIZONTAL TYPE):
AE Type Pump Cross Sectional Drawing
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FIRE WATER PUMP (HORIZONTAL TYPE):
Trouble Probable Cause Remedy
Overload on Pump speed high Motor voltage higher than name plate rating will
driver cause the motor to run faster. Either reduce motor
voltage or trim impeller diameter. On other drives,
reduce speed if possible. If speed reduction not
realized, trim impeller diameter.**
Total head lower than Check suction and discharge pressures and
rating determine the total dynamic head. If TDH lower than
ratings, throttle discharge to rated TDH or, if this is
not possible, reduce, impeller diameter.**
Tight packing Stop pump – follow proper repacking procedure.
Check for scored sleeve; and for sleeve run-out if
packing wears rapidly. Replace sleeve and packing
as required.
Liquid is of higher Check with Peerless distributor to determine if a
specific gravity or larger motor is required.
viscosity than rating
Mechanical trouble of See if pump and motor turn freely. Check impeller fit,
pump or driver shaft straightness and ball bearings.
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Pump vibrates Driver unbalanced Disconnect driver and operate it alone. Check pump
or is noisy for large pieces of debris, such as wood, rags, etc.
Misalignment Realign pumping unit.
Cracked foundation Replace foundation.
Worn ball bearings Replace bearings. Check lubricants for proper

grade. Check pump alignment.
Failure to Pump not primed Reprime.
deliver liquid or
sufficient Pump not up to speed Check for low motor voltage or motor overload. other
pressure drives, increase driver speed when possible.
Discharge head too Check to see that all discharge valves are opened
high and the discharge line is free from obstructions. In
some cases, the installation has to be altered or a
pump of suitable rating
must be provided.
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Failure to Insufficient available Check NPSH requirements of pump and increase
deliver liquid or NPSH system NPSH accordingly.
sufficient
Incorrect direction of Check the impeller assembly for correct rotation
pressure
rotation either by removing upper case or through priming
connection. Check rotation of driver.
Air leaks in suction Tighten packing. Check for air leaks between sleeve
line or through stuffing and shaft and replace O-ring if there is an air leak.
boxes Check all suction line joints for bad gaskets and
loose joints.
Impeller passages Disassemble the pump and clean impeller.
restricted
Worn wearing rings Replace worn parts.
Damaged impeller Replace or repair impeller.
Foot valve too small Replace with adequate size foot valve or clean foot
or restricted by dirt. valve.
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Pump loses Air leaks in suction Tighten packing. Check for air leaks between sleeve
prime after line and shaft and replace O-ring if there is an air leak.
starting Check all suction line joints for bad gaskets and
loose joints.
Insufficient available Check NPSH requirements of the pump and
NPSH increase the system available NPSH
accordingly.
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DIESEL ENGINE DRIVEN FIRE WATER PUMP (VERTICAL TURBINE):
Running
1. The pump should be shut down at once, and the trouble corrected (refer
to Table 1 - Fault Finding Chart attached below), if the pump is running at
rated speed and any of the following defects occur:
a) No liquid delivered.
b) Not enough liquid delivered.
c) Not enough pressure.
d) Loss of liquid after starting.
e) Vibration.
f) Motor runs hot.
g) Cavitation (noise).
h) Pump bearing overheat.
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FIRE WATER PUMP (VERTICAL TURBINE):
Stopping
1. Slowly close delivery valve and shut down driving unit in accordance with
manufacturers' instructions.
2. Shut off external sealing liquid supply, if specified, to relieve stuffing box
pressure.
3. Successful operation of the pumps depends on accurate alignment. It is
recommended to recheck the alignment after preliminary running.
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Impeller too small.
●
TRAINING (O&M) PAGE- 37
CONFIDENTIAL
MHI BUSINESS
Shaft bent.
●
Rotor out of balance.

●
Bearing worn
●
Misalignment of pump
●
and driver.
Foundation not rigid.
●
Lubricating grease or
●
dirty oil or contaminated.

Voltage and/or frequency
●
lower than rating.

Defects in motor.
●
Rotor binding.
●
Damaged impeller.
●
●
Excessive impeller
●
clearance.
FIRE WATER PUMP (VERTICAL TURBINE):
Wrong direction of
●
rotation.
Impeller blocked.
●
●
Insufficient
●
●
submergence.
Liquid density higher
Fault and Remedial Action (Table 1)
●
than rating.
Viscosity of liquid greater
●
●
than rating
Not enough NPSHa.
●
●
Discharge head too high
●
●
(above rating).
G-10 FIRE FIGHTING SYSTEM
Air or gas in liquid.
●
Air leak in mechanical
●
seal.
Speed too high.
●
Speed too low.
●
Pump not primed.
Excessive noise from
Excessive vibration.
Probable
No liquid delivered.
Pump bearings run

Cause
hotter than normal.

Loss of liquid after
Liquid delivered at
Motor runs hotter

Insufficient liquid
pump cavitation
low pressure.
than normal.
Potential
delivered.
Fault or
starting.
Defect

FIRE WATER PUMP (HORIZONTAL INDUCTION MOTOR):
Frequency of Inspection
Frequency of Inspection
Probable Cause
Clean Conditions Severe Conditions
Stator winding (including bracing and support structures, Yearly Quarterly
coil end connections, insulation resistance check)
Rotor end ring (or end turns) Yearly Yearly
Rotor removal (rotor and stator bore) Every 5 years Every 5 years
Stator core (with rotor removed) Every 5 years Every 5 years
Brushes and collector rings Quarterly Monthly
Bearing inspection Every 5 years Yearly
Bearing lubrication Twice Yearly Bi-Monthly
Separate lube system (if supplied) Quarterly Monthly
Top cover (filters) Quarterly Monthly
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Maintenance – Grease Recommendation
General:
• The antifriction bearings used on this unit are grease lubricated. Although
the amount of grease required to lubricate antifriction bearings is not great,
it is essential that grease always be present, that the grease be of the
correct type and that it be clean and free of contamination.
• Bearings should be lubricated once every six months for normal,
applications associated with moderate to average environmental
conditions of dirt, moisture and heat.
• For more severe conditions of any one or more of the above environmental
conditions, the lubrication frequency should be increased to every two
months.
• It is important that end shield vibration and bearing noise be monitored.
• Some conditions which can cause bearing failures to occur are as follows:
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Maintenance – Grease Recommendation
General (contd. from previous page):
1. Insufficient grease, or too much grease.
2. Incorrect grease specification.
3. Ambient temperature conditions either too hot or too cold for the
viscosity of the grease being used.
4. Contaminated grease.
5. Misalignment of unit and driven equipment (in parallel, angular or axial
misalignment).
6. Seals too tight.
7. Bearing operated longer than design life (L10 130,000 hours for direct
drive) (L10 40,000 hours for belted drive) will have an increased risk of
failure.
Note: If one or both bearings exhibit an increase in vibration, noise or temperature, above the normal
operating conditions, the unit should be shut down and the cause determined and corrected.
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Overall view of motor
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General view of Antifriction bearing
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Trouble Shooting Chart
Trouble Possible Cause Action
Motor will not Power not connected Connect power to control, and control
start to motor.
Check contacts. Low Voltage Check motor nameplate value

with bus voltage.
Wrong control connections Check connections with control wiring diagram.
Driven machine locked Disconnect motor from load. If motor starts

satisfactorily, check driven machine.
Open circuit in stator or Measure/ compare winding resistance of each

rotor winding phase.
Winding grounded Test for grounded winding.
Excessive load torque Check motor capability.
Overload control trip Wait for motor to cool. Try starting again
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Noise or Motor running single phase Stop motor. Then try to start. It will not start on
vibration single phase. Check for “Open” in one of the
lines or circuits.
Supply bus unbalanced Check balance by measuring current and

voltage in each phase. Correct the power
supply to obtain balanced voltages.
Misalignment Check parallel, angular and axial alignment.
Air gap not uniform. Center the rotor.

(Machines furnished
without one bearing)
Noisy ball bearings Check lubrication. Replace bearings if noise is

persistent and excessive.
Loose on foundation Realign machine. Tighten hold-down bolts.
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Noise or Foreign material inside unit Clean inside for unit.
vibration
(cont’d) Shorted field turns Check impedance of each pole. Determine if
(synchronous) one pole has noticeable difference.
Overheating Overloaded Measure loading with ammeter and compare
with full load current on nameplate. Reduce
load.
Electrical load unbalance Check for voltage unbalance or single phasing.
Restricted ventilation Clean filters, air passages and windings. Check

water cooling if applicable.
Incorrect voltage and Check nameplate values with power supply.

frequency. Also check voltage at terminals with machine
under full load.
Stator winding shorted. Inspect winding for damage. Obtain expert help
(line-to line) for repair.
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Overheating Stator winding ground Inspect winding for damage. Obtain expert help
(cont’d) (line-to-ground) for repair.
Incorrect field current See nameplate - apply correct field.

(synchronous)
Incorrect speed Check speed, compare with nameplate.

Bearings Alignment Check parallel, angular and axial alignment.
overheating Correct as required.
(journal type)
Insufficient oil Add oil; if oil supply is very low, drain, flush with
clean oil, and refill.
Contamination in oil or Drain the oil. Flush with clean oil & relubricate
improper grade of oil using oil viscosity specified on nameplate.
Oil rings rotating slowly or Oil ring has worn spot, replace with new ring.
not rotating at all (if oil
rings are used).
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Bearings Rings bent or otherwise Replace oil rings.
overheating damaged in reassembling.
(journal type)
(cont’d) Oil seals bound up or Replace seals.
damaged.
Bearings Noisy Defective bearings or Replace bearings or resurface shaft.
or Vibrating rough journal.
(antifriction
type). Wrong-grade of grease Remove old grease and relubricate using
grease recommended by this Instruction Book.
Insufficient grease Remove relief plug and regrease bearing.

Replace plug after ½ hour running.
Too much grease Remove relief plugs and let motor run until
excess grease is purged. Then reinstall plug.
Defective or damaged Replace bearing.

bearing
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Bearings Noisy Foreign material in grease. Remove relief plug. Purge contaminated
or Vibrating grease from bearings. Relubricate until only
(antifriction clean grease is exiting relief plug.
type) (cont’d)
Low insulation Moisture Dry winding
resistance or
insulation Dirt Clean winding
failure.
Conducting particles have Obtain expert help for repair
penetrated insulation.
Mechanical damage to Obtain expert help for repair.

insulation.
Voltage surges have Obtain expert help for repair

damaged insulation.
Excessive temperatures Obtain expert help for repair
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Wound rotor Excessive impedance Use adequately-sized conductors
motor: between unit and rotor
Motor runs at control
reduce speed
with external Wrong connections. Check stator, rotor and exciter connections,
resistance out check control wiring.
of circuit. Open circuit in rotor
(including cable to control). Test by “ringing out” circuit and repair.
Synchronous Wrong connections Check stator, rotor and exciter connections,
generator: check regulator wiring.
Failure of the
machine to Open circuits Test by “ring out” circuit and repair.
produce rated
output. Prime mover Check speed, run at rated speed.
Inadequate excitation Check excitation. Compare with nameplate

and correct.
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Synchronous Shorted field turns Impedance check all poles – determine if one
generator: pole is noticeably less than others.
Failure of the
machine to Ground in field leads Check lead insulation – check condition where
produce rated leads exit shaft.
output (cont’d)
Brushes Overload Check for overload with ammeter and eliminate
sparking overload. Clean rings, adjust brush pressure
and replace brushes.
Dirt between brush & ring Clean rings, brushes and brush rigging.
Brushes stuck in holders Use correct brushes, clean brush holders.
Incorrect brush tension Check brush tension and correct.
Rough collector rings Stone or turn rings.
Eccentric rings Turn rings or replace collector.

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FIRE WATER PUMP (SMALL INDUSTRIAL MOTOR):
Affected Parts Difficulty Check Items
Windings Overheating • Calibration of measuring instrument
• Excessive current
• Unbalanced AC current
• Improper or restricted ventilation
• Excessive ambient temperature
• Short circuited coil or windings
• Dirty windings
• Unbalanced voltage
Beadings Overheating • Calibration of measuring instrument
• Misalignment
• Excessive end thrust or radial loading
• Shaft currents
• Excessive or insufficient grease
• Worn out or dirty grease
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FIRE WATER PUMP (SMALL INDUSTRIAL MOTOR):
Affected Parts Difficulty Check Items
Motor Excessive vibration • Unbalance
• Misalignment
• Improper or settled foundation
• Non-uniform air gap
• Rubbing parts
• Bent shaft
• Unbalanced stator current
• Damaged bearing
Insulation Low insulation resistance • Moisture, dirt, metal particles, or other
or insulation failure contaminants on the insulated windings
• Wrong voltage
• Excessive temperature
• Voltage surges
• Mechanical damage
• Excessive vibration with resultant mechanical
damage
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• Foam System
• CO2 System
• FM-200 System
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FIRE WATER PUMP (DIESEL ENGINES):
Make : Caterpillar (Model : 3412 Industrial Engine)
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ENGINE PUMP MANUAL STARTING INSTRUCTIONS
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ENGINE PUMP MANUAL STARTING INSTRUCTIONS
Manual Starting
Instructions
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Maintenance Recommendations
Cooling:
CAUTION
* Coolant should be drained and replaced “Every 2000 Service Meter units”.
* Never add coolant to an overheated engine; allow the engined to cool first.
* Never use both the liquid cooling system inhibitor and coolant elements at
the same time.
• Whenever draining and refilling cooling system, always recheck the coolant
level when the engines reaches normal operating temperature.
• Filling at over 19 lit/min can cause air pockets in the cooling system.
• Operate with a thermostat in the cooling system all year-around. Cooling
system problems can rise without a thermostat.
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Electrical:
CAUTION
* When using jumper cables to start the engine, be sure to connect in
parallel: +ve to +ve and –ve to –ve.
Scheduled Oil Sampling:

• Use Scheduled Oil Sampling to monitor the engine’s condition and
maintenance requirements.
• Each oil sample should be taken when the oil is hot, and well mixed, to
insure a sample which is representative of the oil in the compartment.
• Consult manufacturer for complete information, and assistance in
establishing s Scheduled Oil Sampling.
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Fuel:
CAUTION
* Fill fuel tank at the end of each day of operation to drive out the moisture
laden air and to prevent condensation.
* Do not fill the tank to the brim. The fuel expands when it gets warm and
may overflow.
● Water and sediment should be drained from the fuel tank at the start of
each shift or after the fuel tank has been filled and allowed to stand for 5 to
10 minutes.
● Drain fuel tank of moisture and sediment as required by prevailing
conditions.
Air Intake:
• Service air cleaners when RED band in indicator locks in visible position.
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Troubleshooting
Possible Cause Remedy
1. ENGINE FAILS TO START
No Fuel to Engine Check for empty fuel tank, plugged fuel tank connections, obstructed or kinked
fuel suction lines, fuel transfer pump failure, or plugged fuel filters.
Shutoff Solenoid Sticking Solenoid must be energized to shut off engine. Actuate the control that operates
(optional equipment) the shutoff solenoid and listen for a clicking sound. If clicking sound is not evident
and engine will not start, remove the solenoid. Again try to start the engine. If the
engine starts, the solenoid is bad. Replace the solenoid.
Fuel Transfer Pump At cranking speed, the fuel transfer pump should supply fuel to the engine at 3
PSI (20 kPa). If fuel pressure is less than 3 PSI (20 kPa), replace the fuel filter.
Check for air fuel system, sticking, binding or defective fuel bypass valve. If
pressure is still low, replace the fuel transfer pump.
Engine Improperly Timed See your authorized dealer.
Glow Plug Failure Check glow plugs.
Automatic and Safety Check shutoff controls to ensure they are set properly. See Starting Procedures.
Shutoff Controls
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Troubleshooting
2. MISFIRING
Defective Fuel Injection Run the engine at the speed where the defect is most pronounced. Momentarily
Nozzle or Fuel Pump loosen the fuel line nut on the injection pump to “cut out” that cylinder. Check each
cylinder In this manner. If one is found where loosening makes no difference in
irregular operation, the pump and nozzle for only that cylinder need be treated.
Improper Valve Lash Set to specified clearance.
Incorrect Fuel Injection See your authorized dealer.
Timing
Low Fuel Supply Check fuel supply line for leaks or kinks, air in fuel system. sticking, binding, or
Pressure defective fuel bypass valve. Replace fuel filter. Check fuel pressure. Fuel transfer
pump should supply fuel at 20 to 30 PSI (1.4 to 2.1 kg/cm2) to the engine when
the engine is fully loaded.
Broken or Leaking High Replace the line.
Pressure Fuel Line
Air in Fuel System Find source of air entry and correct. Bleed system.
Bent or Broken Push Rod Replace push rod.
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Troubleshooting
3. STALLS AT LOW SPEED
Idle Speed Too Low See your authorized dealer.
Low Fuel Supply Check fuel supply line for leaks or kinks, air in fuel system. sticking, binding, or
pump shall supply fuel to 20 to 30 PSI (1.4 to 2.1 kg/cm2) to the engine when the
engine is fully loaded.
Defective Fuel Nozzle Replace nozzle.
Defective or Damaged Replace damaged or defective parts.
Fuel Injection Pumps
High Parasitic Loads Check for excessive loading due to auxiliary attachments.
4. ERRATIC ENGINE SPEED
Governor Control Adjust external linkage to obtain sufficient travel. Replace if damaged, bent, or
Linkage linkage is too short.
Governor Failure Look for damaged or broken springs, linkage, or other components. Determine if
the rack can be moved manually. If any distress is noted in any of these
components, replace as necessary.
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Troubleshooting
5. LOW POWER
Fuel Nozzle Failure Run the engine at the speed where the defect is most pronounced. Momentarily
loosen the fuel line nut on the injection pump to ‘cut out” that cylinder. Check each
cylinder in this manner. If one is found where loosening makes no difference in
irregular operation, the pump and nozzle for only that cylinder need be tested.
Poor Quality Fuel Drain, clean and bleed fuel system. Replace fuel filter. Fill fuel tank with proper
grade of fuel.
Turbocharger Carboned Inspect and repair or replace turbocharger as necessary.
or Otherwise Dragging
Leaks in Air Induction Check inlet manifold pressure. Check air cleaner for restriction.
System
Timing
Excessive Valve Lash Set to specified clearance.
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Troubleshooting
5. LOW POWER (CONT’D)
Low Fuel Supply Check fuel supply line for leaks or kinks, air in fuel system, sticking, binding or
pump should supply fuel to 20 to 30 PSI (1.4 to 2.1 kg/cm2) to the engine when
the engine is fully loaded.
6. EXCESSIVE VIBRATION
Loose, Worn or Defective Tighten all mounting bolts securely. Replace components as necessary.
Engine Mounts
Loose Pulley and Retighten.
Damper
Loose or Worn Coupling Inspect, align and tighten coupling to driven equipment.
on Driven Equipment
Defective Damper or Replace damper or pulley.
Pulley
Misfiring See ITEM 2.
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Troubleshooting
6. EXCESSIVE VIBRATION (CONT’D)
Unbalanced Fan Blade Check by loosening or removing fan belts, and operating engine for ‘short
duration” at affected speed range to see if vibration is still present. If not, replace
fan assembly.
7. HEAVY COMBUSTION KNOCK
Air in Fuel System Bleed air from system.
Defective Fuel Injection Replace.
Pump Plunger and Barrel
Assembly
Defective Fuel Injection Replace.
Nozzle
Timing
8. VALVE TRAIN CLICKING NOISE
Excessive Valve Lash Set to specified clearance.
Broken Valve Spring(s) Replace valve spring(s) and all other damaged components.
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Troubleshooting
8. VALVE TRAIN CLICKING NOISE (CONT’D)
Insufficient Lubrication Check lubrication in valve compartment. Should be very wet at all speeds. Oil
passages should be cleaned, especially those leading to the cylinder head.
9. OIL IN COOLANT
Failed Oil Cooler Core Replace oil cooler core.
Failed Head or Spacer Replace head and spacer plate gaskets.
Plate Gaskets
Cracked or Defective Replace cylinder block.
Cylinder Block
Cracked or Defective Replace cylinder head.
Head
10. MECHANICAL KNOCK
Engine Connecting Rod Replace the bearing. Check the connecting rod arid
Bearing Failure crankshaft. Replace if necessary.
Main Bearing Failure Replace bearings
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Troubleshooting
10. MECHANICAL KNOCK (CONT’D)
Damaged Timing Gear Replace components as necessary.
Train
Broken Crankshaft Replace crankshaft.
Fuel Dilution of Correct fuel leakage into crankcase oil.
Crankcase Oil
11. EXCESSIVE FUEL CONSUMPTION
Fuel System Leaks Large changes in fuel consumption may result. Internal leaks will probably be
accompanied by low engine oil pressure and increased oil level in the engine oil
sump. Replace leaking components.
Fuel and Combustion Small but measurable increases in fuel consumption may be the result of
Knock defective fuel nozzles, misfiring or factors contributing to loss of power. See ITEM
2 and ITEM 5.
Timing
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Troubleshooting
12. LOUD VALVE TRAIN NOISE
Bent or Broken Valves Replace damaged parts.
Broken Camshaft Replace all damaged parts. Clean engine thoroughly.
Broken or Severely Worn Replace camshaft and valve lifters, Check for sticking valves and bent valve
Valve Lifters stems. Clean engine thoroughly. Set valve lash to specified clearance.
13. EXCESSIVE VALVE LASH
Severely Worn Cam Check valve lash. Replace camshaft and followers. Clean engine thoroughly. Set
Lobes valve lash to specified clearance.
Broken or Severely Worn Replace valve lifters. Check camshaft for wear. Check for sticking valves and bent
Valve Lifters valve stems. Clean engine thoroughly. Set valve lash to specified clearance.
Valve Tip Wear Set valve lash to specified clearance. If wear is excessive, replace valve.
Moderate Valve Lifter Set valve lash to specified clearance. If wear is excessive, replace valve litter.
Face Wear
Push Rod Wear Set valve lash to specified clearance. If wear is excessive, replace push rod.
Rocker Arm Anvil Wear Set valve lash to specified clearance. If wear is excessive, replace rocker arm.
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Troubleshooting
13. EXCESSIVE VALVE LASH (CONT’D)
Insufficient Lubrication Check lubrication in valve should be very wet at high idle speeds. but only damp
at low idle. Oil passages should be cleaned, especially those leading to the
cylinder head.
14. VALVE SPRING RETAINER FREE
Broken Keepers Extensive engine damage may result from dropped valve. Replace all damaged
part.
Broken Valve Spring Replace valve spring.
Broken Valve Replace valve and any other damaged parts.
15. SLOBBER
Excessive Valve Guide Recondition cylinder head assembly.’
Wear
Excessive Lubricating Oil Check rocker arm shaft and plugs to assure that they are in place.
in Valve Compartment
Worn Piston Rings and/or Inspect and replace components as necessary.
Liners
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Troubleshooting
16. VALVE LASH CLOSE-UP
Valve Face and/or Seat Adjust valves to specified clearance. Recondition cylinder head.
Wear
17. PREMATURE ENGINE WEAR
Intake Piping Failure (Air Inspect all gaskets and piping for leaks. Repair all leaks.
Cleaner) Lubricating Oil
Excessive Fuel Dilution Replace leaking components. This will probably be accompanied by high fuel
of Lubricating Oil consumption and low engine oil pressure.
Tighten fuel injection line fittings under valve cover.
Dirt in Lubricating Oil Locate and correct source of dirt entry. Change lubricating oil. Change oil filter.
18. COOLANT IN ENGINE LUB OIL
Oil Cooler Failure Replace oil cooler core.
Cylinder Head Gasket Replace gasket. Maintain proper torque on cylinder head bolts.
Failure
Cracked or Defective Replace cylinder head / block.
Cylinder Head / Block
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Troubleshooting
18. COOLANT IN ENGINE LUB OIL (CONT’D)
Cylinder Liner Seal Replace seals.
Leaking
Cracked or Defective Replace cylinder liners.
Cylinder Liners
19. EXCESSIVE BLACK OR GREY SMOKE
Insufficient Combustion Check air cleaner for restriction. Check inlet manifold pressure. Inspect
Air turbocharger for proper operation.
Fuel Nozzle Plugged or Replace nozzle.
Leaking
Timing
Fuel Ratio Control Adjust fuel ratio control.
Improperly Adjusted
20. EXCESSIVE WHITE OR BLUE SMOKE
Valve Guides Worn Recondition cylinder head assembly.
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Troubleshooting
20. EXCESSIVE WHITE OR BLUE SMOKE (CONT’D)
Piston Rings Worn, Stuck Replace.
or Broken
High Crankcase Oil Level Avoid overfilling. Determine cause and drain excess oil.
Misfiring See ITEM 2.
Fuel Injection Pump See your authorized dealer.
Timing Wrong
Air In Fuel System Bleed fuel system.
21. LOW ENGINE OIL PRESSURE
Engine Oil Diluted with Check lip-type seal on fuel transfer pump drive shaft. Drain crankcase and refill
Fuel Oil with clean lubricant.
Excessive Crankshaft Replace bearings and/or crankshaft: Check oil filter operation.
Bearing Clearance
Excessive Timing Gear Inspect bearings and replace components as necessary.
Bearing Clearances
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Troubleshooting
21. LOW ENGINE OIL PRESSURE (CONT’D)
Excessive Rocker Arm Check lubrication. Replace components as necessary.
Bore or Rocker Arm
Shaft Wear
Defective Oil Pump Repair or replace.
Defective Suction Bell Replace.
Clogged Oil Filter or Repair or replace as necessary.
Cooler
Oil Pump Relief Valve Clean valve and housing. Replace if necessary.
Stuck
22. HIGH LUB OIL CONSUMPTION
Oil Leaks Replace gaskets or seals and tighten all connections.
Excessive Oil to Intake See ITEM 15. Valve Guides.
Excessive Valve Guide See ITEM 15.
Wear
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Troubleshooting
22. HIGH LUB OIL CONSUMPTION (CONT’D)
Crankcase Oil Level Too Avoid overfilling. Determine cause and drain excess oil.
High
High Oil Temperature Check oil cooler bypass valve. Replace if defective. Clean oil cooler core.
Worn Piston Rings and/or Replace components as necessary.
Liner
23. ABNORMAL ENGINE COOLANT TEMPERATURE
Combustion Gases in Determine point at which gases enter the system. Repair or replace components
Coolant as necessary.
Defective Water Check temperature regulator for proper opening temperature and correct
Temperature Regulator installation. Check temperature gauge. Replace if necessary.
or Temperature Gauge
Coolant Level Low Determine cause - replace leaking gaskets and hoses. Tighten connections. Add
coolant.
Air Flow Through Remove all debris from outer surface of radiator.
Radiator Restricted
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Troubleshooting
23. ABNORMAL ENGINE COOLANT TEMPERATURE (CONT’D)
Defective Water Pump Check water pump impeller. Repair water pump as necessary.
Radiator Small for Engine Install correct size radiator.

Application
Fan Improperly Position fan correctly.
Positioned in Shroud or
Not Shrouded
Timing
Incorrect Water Piping Check shunt line (if equipped) and vent line for correct installation.
Connections from Engine
to Radiator
24. STARING MOTOR FAILS TO CRANK
Low Output from Battery Check battery and charge or replace.
Defective Wiring or Repair or replace.
Switch
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Troubleshooting
24. STARING MOTOR FAILS TO CRANK (CONT’D)
Defective Solenoid Replace.
Defective Starting Motor Repair.
25. ALTERNATOR FAILS TO CHARGE
Drive Belt Loose Adjust belt.
Open or High Resistance Inspect all cables and connectors. Clean. retighten or replace defective parts.
in Charging or Ground
Return Circuits or Battery
Connections
Excessively Worn, Open Replace brush assembly.
or Defective Brushes
Open Rotor Field Coil Replace rotor assembly.
26. ALTERNATOR CHARGING RATE LOW OR UNSTEADY
Drive Belt Loose Adjust belt.
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Troubleshooting
26. ALTERNATOR CHARGING RATE LOW OR UNSTEADY (CONT’D)
Intermittent or High Inspect all cables and connectors. Clean, retighten or replace defective parts.
Resistance in Charging
or Ground Return Circuits
or Battery Connections
Excessively Worn, Sticky, Replace brush assembly.
or Defective Brushes
Faulty Regulator Replace regulator.
Shorted or Open Rectifier Replace defective rectifier diode assembly in alternator.
Diodes
Grounded or Shorted Replace rotor assembly.
Rotor
27. ALTERNATOR CHARGING RATE HIGH
Loose Connections Tighten connections to alternator and regulator.
Defective Regulator Replace regulator.
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Troubleshooting
28. ALTERNATOR NOISY
Defective Drive Belt Replace belt.
Misaligned Belt or Pulley Align drive pulley, alternator pulley and belt.
Loose Pulley Tighten pulley nut. If keyway is worn, install a new pulley.
Worn Bearings Replace bearings.
Shorted Rectifiers in Replace diode assembly.

Alternator
Armature or Rotor Shaft Replace component.
Bent
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• Foam System
• CO2 System
• FM-200 System
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Water Spray Deluge System:
Deluge Valve Set
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Deluge Valve Set – Graphical Representation
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Maintenance instruction of deluge valve set
In addition to common tests regular maintenance of all parts must be carried
out for operating safety of the deluge valve sets.
Maintenance work should be carried out at least once a year, testing the
main valves and fittings like: deluge valve and solenoid valve on their
availability in case of an authentic actuation - e.g. activation by a control
panel.
The following maintenance sequence must be observed:
1. Functional test of the deluge valve set

• by detector activation in case of an electr. Actuation
• with a test ball valve in case of hydraulic actuation and electric
actuation pre-action and combination of these
To avoid flooding the pipework, the gate valve of the set located at the output
side can be closed.
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Maintenance instruction of deluge valve set (cont’d)
2. Maintenance of the actuation valves and fittings according to the following
maintenance instructions:
- Deluge valve (DN 50 -200)
- Causes of trouble at the deluge valve set
- Solenoid valves
- Impulse solenoid valve
- Causes of trouble at the impulse solenoid valve
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Maintenance regulation of deluge valve set (see figure attached below)
• The deluge valve set and the corresponding actuation system, e.g. control
panel, must always be released and a functional test must be carried out
before each maintenance of the deluge valve.
• To prevent flooding the nozzle pipework, the gate valve located at the
output side can be closed. See also operating instructions for deluge valve
sets.
• Further maintenance must be carried out as follows:
Ø Close inlet and outlet gate valve at the deluge valve set.
Ø Drain deluge valve, turn 3/2 way valve to test and open the drain valves at the
set.
Ø Unscrew cover (4) (hexagon screws pos. 19 and 20)
Attention: The cover nuts must be loosened simultaneously and carefully
because of the pressure spring (14) located under the cover (4) (danger of
injury).
Ø Remove the pressure spring (14) and pull out and clean complete diaphragm
drive at the valve rod (6) with guide shell (3) and valve disk (7).
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Deluge Valve
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Maintenance regulation of deluge valve set (cont’d)
Ø Clean valve disk gasket (8), diaphragm (13) and o-ring (18) and check on
damages and replace if necessary.
Ø To replace the valve disk gasket and/or diaphragm loosen hexagon screws (11)
and remove compl. valve disk or supporting plates (12) respectively with
diaphragm (13) from the valve rod.
Ø Clean all parts and check on damages, replace if necessary.
Ø Place the valve disk (7) with the inserted o-ring (10), gasket (8) and supporting
plate (9) onto the valve rod (6) and tighten with hexagon nut (11).
Attention: The O-ring (10) must be lubricated!
Ø Insert valve rod with the complete assembled valve disk into the guide shell (3)
or guide bush (5) respectively.
Attention: The sliding surface between guide bush (5) and valve rod (6) must be
lubricated.
Ø Place the supporting plate (12) with the inserted o-rings (10) and the diaphragm
(13), onto the valve rod and tighten or fix with hexagon nuts (11) respectively.
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Maintenance regulation of deluge valve set (cont’d)
Ø Clean the valve interiors, especially the valve seat and o-ring recess.
Ø Lubricate o-ring recess and insert o-ring (18).
Attention: If the o-ring (18) is not exactly placed in the recess and lubricated it
may be damaged when installing the guide shell.
Ø Carefully insert the guide shell (3) with the mounted valve disk and supporting
plates into the deluge valve housing and align according to the screw holes.
Attention: The o-ring (18) must not be damaged or squeezed during this
assembly!
Ø Insert the pressure spring (14) and firmly tighten the housing cover (4) with the
hexagon screws (19) and (20).
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Causes of trouble at the deluge valve set
FAULT CAUSE
Deluge valve does not release • water supply pressure too low
• release valve was not activated or is defective
Deluge valve does not close • release valve is not reversed or still activated (control panel)
• release valve is defective
• sieve or throttle in the strainer of the bypass line is clogged
• valve disk gasket dirty or damaged
Water flows out of the drainage valve • o-ring between valve rod and valve disk is damaged or
missing
• o-rings between valve rod and supporting plates are
damaged or missing
• valve disk gasket dirty or damaged
• diaphragm is damaged
Pressure in the control chamber drops • non-return valve in the bypass line is dirty or damaged
during pressure relief in the water • o-rings between valve rod and supporting plates are
supply damaged or missing
• diaphragm is damaged
Pressure drop in the pre action system • burst / damed sprinkler in the pipework
(with signal at fire alarm panel from • pipework not tight
pressure switch) • leakage at deluge valve set
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Maintenance regulation of solenoid valves
• The solenoid valve must always be released via the control panel or test
detectors and a functional test must always be carried out before each
maintenance.
• The release solenoid valve is of great importance for the availability of the
deluge valve set. Therefore it must always be checked during annual
maintenance intervals and maintained.
• Especially the control part of the impulse solenoid valve differs from a
common 2/2-way solenoid valve. Therefore different regulations must be
observed for maintenance.
Maintenance regulation of impulse solenoid valve (see figure below)
• The control part (coil set) of this valve is hermetically sealed against the
applied pressure media by a formed gasket. Thus, the armature room
cannot become dirty, so that the control part must not be maintained. This
also applies to the adjusting screws (11) with throttle and relief borings.
These adjusting screws (11) are adjusted at the factory and secured
against adjustment by screw retention lacquer.
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Impulse Solenoid Valve
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Maintenance regulation of impulse solenoid valve (cont’d)
Attention: Loosening both coil fastening screws (9) or adjusting the
adjusting screws (protected with red safety lacquer) will result in
malfunctions.
• If necessary, the complete control part (coil set) must be replaced (see
spare parts lists). Thus, maintenance of the impulse solenoid valve is
limited to checking the diaphragm chamber and must be carried out as
follows:
Ø Switch off voltage supply to the solenoid valve (control panel), unscrew or
remove plug head (8) if necessary.
Ø Loosen both diagonally arranged fastening screws (7) (without safety lacquer)
and remove complete coil set (9 - 16).
Attention: The 3 o-rings 6 x 1.5 (14) for sealing the duct connectors are inserted
loosely and may be lost. It is not permissible to loosen or adjust locked screws
(9) or (11) (red safety lacquer).
Ø Loosen 4 pcs. fastening screws (6) (not shown in the drawing) at the valve
housing (1) and remove valve cap (2). Attention: The 2 o-rings 4 x 1.5 (5) for
sealing the duct connectors and the conical spring (4) are inserted loosely and
may be lost.
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Maintenance regulation of impulse solenoid valve (cont’d)
Attention: The 2 o-rings 4 x 1.5 (5) for sealing the duct connectors and the
conical spring (4) are inserted loosely and may be lost.
Ø Clean valve housing (1) and cap (2).
Ø Clean diaphragm (3), conical spring (4) and o-rings (5), check on damages and
replace if necessary.
Ø Insert diaphragm (3), conical spring (4) and o-rings (5) into the valve cap (2) and
screw into the housing (1).
Attention: Correct positioning of components is of high importance to the
reliability performance of the valve. A missing o-ring causes a failure of the
solenoid valve.
Ø Screw-in coil set (9 - 16) and plug head (8) again.
Attention: The position of the coil set (9 - 16) to the flow direction of the valve
(see arrow) must always be observed. An incorrectly assembled coil set (turned
by 180°) reverses the operation of the solenoid valve!
Ø Reconnect voltage supply to the solenoid valve.
Important: Final functional test of the solenoid valve with the control panel or test
detector.
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Causes of trouble at the impulse solenoid valve
FAULT CAUSE
Valve does not open • power supply is missing
• adjusting screws (11) were adjusted without observing the
regulation
• coil set was disassembled or incorrectly mounted without
observing the regulation
• defective diaphragm
• o-rings (5) or (14) are missing or defective
Valve does not close • power supply to the reset coil is missing
• monitoring voltage of the release coil was not resetted
during reversal
regulation
Valve is leaking • diaphragm seat is defective or dirty
regulation
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Preventive Maintenance Procedure
SYSTEM : Water Spray System (Electric Actuation, Electric Actuation with pre action & Hydraulic Actuation)
INTERVAL
No. CHECK ITEM Quarter Half
Weekly Monthly Yearly
Yearly yearly
1 Notify the relevant persons that maintenance work is to be carried out! X
Carry out a visual check on the general state of the deluge valve set
2 and check that valves are in the correct position and are properly X X
secured.
3 Check operating pressures at pressure gauges (12) and (16). X
Remove the padlocks and straps from both up- and downstream
4
isolating valves (2) and (3). X
5 Close downstream isolating valve (3) X
6 Open drain valve (22) at the tube bend X
7 Open manual release valve (5) at the deluge valve station. X
Actuation of the solenoid valve (4) by means of the fire alarm panel
8 (automatic fire detectors of manual release push button) for Electric X
Actuation System only.
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INTERVAL
Yearly yearly
The pressure in the chamber of the deluge valve (1) must drop
9
immediately (gauge reading) X
10 The drip valve (6) must be normally closed. After pressure loss water X
rinse out of the drip valve. Note: The alarm gong shall start to sound.
11 Close upstream isolating valve (2) X
12 Close manual release valve (5) X
13 Check electrical signal from pressure switch (10) to fire alarm panel X
(solenoid valve (4) must be closed).
14 Reset the manual release push button. X
15 Reset the fire alarm panel. X
Opening the test ball valve (32) at the end of the sprinkler pipeline will
create an air pressure loss in the pipework.
16 Check electrical signal from pressure switch (26) in the pre-action line X
to the fire alarm panel (for electric actuation with pre-action system
only)
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INTERVAL
Yearly yearly
17 Close the test ball valve (32) X
18 Reset the fire alarm panel after reaching the air pressure in the X
sprinkler pre action pipework.
19 Close inlet and outlet gate valve at the deluge valve set. X
20 Drain deluge valve, turn 3/2 way valve to test and open the drain X
valves at the set.
Unscrew cover (4) (hexagon screws pos. 19 and 20) of deluge valve
Attention: The cover nuts must be loosened simultaneously and
21
carefully because of the pressure spring (14) located under the cover X
(4) (danger of injury).
Remove the pressure spring (14) and pull out and clean complete
22 diaphragm drive at the valve rod (6) with guide shell (3) and valve X
disk (7).
23 Clean valve disk gasket (8), diaphragm (13) and o-ring (18) and check X
on damages and replace if necessary.
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INTERVAL
Yearly yearly
To replace the valve disk gasket and/or diaphragm loosen hexagon
24 screws (11) and remove complete valve disk or supporting plates (12) X
respectively with diaphragm (13) from the valve rod.
25 Clean all parts and check on damages, replace if necessary. X
Place the valve disk (7) with the inserted o-ring (10), gasket (8) and
26 supporting plate (9) onto the valve rod (6) and tighten with hexagon X
nut (11).
Insert valve rod with the complete assembled valve disk into the guild
27
shell (3) or guild bush (5) respectively. X
Place the supporting plate (12) with the inserted o-rings (10) and the
28 diaphragm (13) onto the valve rod and tighten or fix with hexagon nuts X
(11) respectively.
29 Clean the valve interiors, especially the valve seat and o-ring recess. X
30 Insert o-ring (18) into recess. X
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INTERVAL
Yearly yearly
Carefully insert the guide shell (3) with the mounted valve disk and
supporting plates into the deluge valve housing and align according to
31 the screw holes. X
Attention: The o-ring (18) must not be damaged or squeezed during
this assembly!
Insert the pressure spring (14) and firmly tighten the housing cover (4)
32
with the hexagon screws (19) and (20) . X
33 Recommissioning / function test according to operating instructions. X
MHI BUSINESS
CONFIDENTIAL

• Foam System
• CO2 System
• FM-200 System
MHI BUSINESS
CONFIDENTIAL

Sprinkler System:
MHI BUSINESS
CONFIDENTIAL

Sprinkler System:
Wet Pipe Alarm Valve Set (Type NMX)
MHI BUSINESS
CONFIDENTIAL

Sprinkler System:
Maintenance regulations for wet pipe alarm valve set
In order to assure the safe and reliable operation of the wet pipe alarm valve
set, the operating instructions/operating log book prescribe regular
maintenance in addition to the usual tests and inspections.
The maintenance intervals should be no longer than six months.
Functional checks and maintenance are to be carried out as follows:

Ø Notify the relevant persons that maintenance work is to be carried out!
Ø Carry out a visual check on the general state of the wet pipe alarm valve set and
check that valves are in the correct position and are properly secured.
Ø Check operating pressures at pressure gauges (9) and (10).
Ø Bring about zero setting of pressure gauges (9) and (10) by briefly closing or
opening the pressure gauge shut-off valves (8) and vent valves (7) (functional
check).
Ø Check by-pass pipe (18) and non-return valve (17) for clear passage by closing
pressure gauge shut-off valve (8) and opening the upper vent valve (7): water
must be discharged from the vent valve.
MHI BUSINESS
CONFIDENTIAL

Sprinkler System:
Maintenance regulations for wet pipe alarm valve set (cont’d)
Ø Check that non-return valve (17) closes correctly. To do this, close the lower
pressure gauge shut-off valve (8) and open the lower vent valve (7): when the
non-return valve closes no water must be discharged.
Ø Open test valve (4) and check alarm devices (alarm pressure switch (11) and
alarm gong (12)) for proper functioning.
Ø In systems with a retard chamber the length of the delay must be checked. The
delay is the time between actuation of the wet pipe alarm valve - visibly indicated
by a discharge of water at drip check valve (5) - and the response of the alarm
pressure switch (11) on the retard chamber (15). If the delay is too long, i.e. 30 s,
the 2.5 mm diameter throttle must be cleaned or replaced.
Ø Close test valve (4) and check the valve head of the wet pipe alarm valve set for
integrity of seal. No water must be discharged from drip check valve (5). If the seal
on the valve head is not intact the sprinkler system must be drained and
maintenance carried out on the wet pipe alarm valve, as described in the later part
of this section.
Ø Check and, if necessary, clean the strainer (13) in the alarm gong pipe.
MHI BUSINESS
CONFIDENTIAL

Sprinkler System:
Maintenance regulations for wet pipe alarm valve set (cont’d)
Ø Check the shut-off valves (gate valves, ball valves, drain valve) for integrity of seal
and position them for operational readiness.
Ø Secure the shut-off valve in position with a strap and padlock. This precaution can
be dispensed with in systems with electric monitoring.
Ø In systems with electric monitoring the monitoring devices and their transmission
systems must be checked at the alarm shut-off valve (16) and the gate valve (3).
MHI BUSINESS
CONFIDENTIAL

Sprinkler System:
Wet Pipe Alarm Valve
MHI BUSINESS
CONFIDENTIAL

Sprinkler System:
Maintenance of wet pipe alarm valve
The wet pipe alarm valve is largely maintenance free and must simply be
checked for integrity of seal at the half yearly maintenance interval when the
wet pipe alarm valve set is subjected to a test alarm.
In order to assure perfect functioning, preventive maintenance should be
carried out on it annually. This should include cleaning of the inside of the
valve as described below:
Ø Close the valve set gate valve and drain the sprinkler pipework.
Ø Unscrew the inspection cover (5) and clean the inside of the valve.
Ø Remove the retaining screws (7), the bearing pin (8) and the complete valve head.
Ø Clean the valve head and check the gasket (2) for damage, e.g. crushing,
replacing the gasket if necessary. At a pinch, the old gasket can be simply turned
over.
Ø Check the O-rings (3) on the remaining screws and, if necessary, replace.
Ø Re-install the complete valve set by following the above procedure in reverse
order.
MHI BUSINESS
CONFIDENTIAL

Sprinkler System:
Maintenance of wet pipe alarm valve (cont’d)
Caution: The mounting of the valve head including bearing pin and retaining
screws must be adequately greased.
Ø Check the gasket (1) on the inspection cover (5) for damage and, if necessary,
replace.
Ø Screw the inspection cover back on and return the wet pipe alarm valve set to
service.
MHI BUSINESS
CONFIDENTIAL

Sprinkler System:
Troubleshooting of alarm valve set
FAULT CAUSE
Alarm pressure switch (11) fails to • Gate valve (3) is closed
respond when test valve (4) opens • Alarm shut-off valve (16) is closed
• Alarm pressure switch (11) is faulty or the nozzle is blocked
• Strainer (13) is blocked
• Test valve (4) is faulty or blocked
• Transmission ways (wiring) faulty or loose.
Alarm gong (12) fails to function • Gate valve (3) is closed

• Alarm shut-off valve (16) is closed
• Alarm gong (12) is faulty (hammer, bearings, etc.)
• Throttle in the turbine is blocked
• Alarm gong is frozen up
• Strainer (13) is blocked
Intermittent alarm • The sprinkler pipework has not been adequately vented.
Extremely important when very extensive pipework is fitted!
MHI BUSINESS
CONFIDENTIAL

Sprinkler System:
Troubleshooting of alarm valve set
FAULT CAUSE
False alarm • Pressure gauge shut-off valve (8) in the by-pass pipe
• (18) is closed.
• Flow in the by-pass pipe (18) is obstructed. Non return valve
(17) is jammed or dirty.
• Very large fluctuation in pressure (e.g. water hammer) in the
water supply line which the by-pass pipe is unable to
compensate for. It may be necessary to fit a retard chamber!
Water drips constantly from the drip • The valve head gasket in the wet pipe alarm valve is not
check valve tight (dirty or damaged gasket) (cf. maintenance of the wet
pipe alarm valve set)
Delay is too long. • Throttle on the retard chamber is blocked (option)

i.e. > 30 s
MHI BUSINESS
CONFIDENTIAL

Sprinkler System:
SYSTEM : Wet Alarm Valve System
INTERVAL
Yearly yearly
1 Notify the relevant persons that maintenance work is to be carried out! X
Carry out a visual check on the general state of the wet pipe alarm
2 valve set and check that valves are in the correct position and are X
properly secured.
To refer to above figure for wet pipe alarm valve set:
3
Check operating pressures at pressure gauges (9) and (10). X
Bring about zero setting of pressure gauges (9) and (10) by briefly
4 closing or opening the pressure gauge shut-off valves (8) and vent X
valves (7) (functional check).
Check by-pass pipe (18) and non-return valve (17) for clear passage
5 by closing pressure gauge shut-off valve (8) and opening the upper X
vent valve (7): water must be discharge from the vent valve.
Check that non-return valve (17) closes correctly. To do this, close the
6 lower pressure gauge shut-off valve (8) and open the lower vent valve X
(7): when the non-return valve closes no water must be discharged.
MHI BUSINESS
CONFIDENTIAL

Sprinkler System:
Preventive Maintenance Procedure (cont’d)
INTERVAL
Yearly yearly
Open test valve (4) and check alarm devices (alarm pressure switch
7
(11) and alarm gong (12)) for proper functioning. X
Close test valve (4) and check the valve head of the wet pipe alarm
valve set for integrity of seal. No water must be discharged from drip
8 check valve (5). If the seal on the valve head is not intact the sprinkler X
system must be drained and maintenance carried out on the wet pipe
alarm valve, as described in item 12 below.
Check and, if necessary, clean the strainer (13) in the alarm gong
9
pipe. X
10 Check the shut-off valves (gate valves, ball valves, drain valve) for X
integrity of seal and position them for operational readiness.
11 Secure the shut-off valve in position with a strap and padlock. This X
precaution can be dispensed with in systems with electric monitoring.
12 Cleaning of the inside of the wet alarm valve: X

To refer to above figure for wet pipe alarm valve
13 Close the valve set gate valve and drain the sprinkler pipework. X
MHI BUSINESS
CONFIDENTIAL

Sprinkler System:
INTERVAL
Yearly yearly
14 Unscrew the inspection cover (5) and clean the inside of the valve. X
Remove the retaining screws (7), the bearing pin (8) and the complete
15
valve head. X
Clean the valve head and check the gasket (2) for damage, e.g.
16 crushing, replacing the gasket if necessary. At a pinch, the old gasket X
can be simply turned over.
Check the O-rings (3) on the remaining screws and, if necessary,
17
replace. X
Re-install the complete valve set by following the above procedure in
reverse order.
18
Caution: The mounting of the valve head including bearing pin and X
retaining screws must be adequately greased.
Check the gasket (1) on the inspection cover (5) for damage and, if
19
necessary, replace. X
MHI BUSINESS
CONFIDENTIAL

Sprinkler System:
INTERVAL
No. CHECK ITEM
Weekly Monthly Quarter Half Yearly
Yearly yearly
Screw the inspection cover back on and return the wet pipe alarm
20
valve set to service in accordance with operating regulations. X
21 Set the system in operation again. X
22 Notify the relevant persons that maintenance work is completed. X
MHI BUSINESS
CONFIDENTIAL

• Foam System
• CO2 System
• FM-200 System
MHI BUSINESS
CONFIDENTIAL
OPERATION & CONTROL

Indoor & Outdoor Fire Hydrant System:
1. Ready for operation Hydrant Hose Box Systems with Hose Rack
• Ensure that all components are stored in the hose box cabinets.
• Ensure hydrant valves and the nozzle are closed.
• Ensure that the fire hose is connected securely to the angle valve
DN40 and nozzle.
• Ensure that there is no obstruction within the hose rack.
2. Operating procedure Hydrant System

The typical operating procedures are as follows:
MHI BUSINESS
CONFIDENTIAL
OPERATION & CONTROL

3. Ready for operation Outdoor Hydrant
• Ensure that all components are stored in the hose cabinets.
• Ensure that the underground seated gate valve is in open position.
4. Operating procedure Outdoor Hydrant

• Open the door of the hose cabinet.
• Pull the fire hose all the way.
• Connect the fire hose coupling to hose connection at the dry barrel
hydrant and to the Nozzle
• Open the dry barrel hydrant by using the hydrant wrench
• Keep a safe distance to the fire and open the nozzle
• When the nozzle is opened, water will shoot out from the opening.
MHI BUSINESS
CONFIDENTIAL
OPERATION & CONTROL

5 After operating Indoor Hydrant
• Close the angle valve DN40.
• Pull in the hose into the rack. Push out all water from the hose.
• Close the nozzle fully
• Inspect if there are any damages on the hose or nozzle
6 After operating Outdoor Hydrant

• Close the nozzle and the dry barrel hydrant.
• Disconnect the fire hose coupling from hose connection.
• Inspect if there are any mechanical damages on the hose or nozzle.
• Dry and roll up the fire hose and place it in position inside the hydrant
hose cabinet.
• Check that all components are stored in the outdoor hydrant cabinet.
MHI BUSINESS
CONFIDENTIAL

Maintenance Procedure
1. Monthly Check
1.1 Hydrant Hose Box System with Hose Rack
1) Check the hydrant box for any corrosion or damages
2) Ensure that the fire hose is connected securely to the angle valve
DN40 and nozzle.
3) Ensure hydrant valves and the nozzle are closed.
4) Check all components are stored in the hose cabinet
5) Check all parts for damages
6) Ensure that there is no obstruction within the hose rack
7) Check water supply piping up to the angle valves for any damage
or corrosion
8) Check the foam content (mind. 60 ltr.) to the foam hose station.
MHI BUSINESS
CONFIDENTIAL

Maintenance Procedure
1.2 Outdoor Hydrant System
1) Check the dry barrel hydrant and hose cabinet for any corrosion or
damages
2) Check all components are stored in the hose cabinet
3) Check all parts for damages
4) Check visual water supply piping for any corrosion or damages
2. Yearly Test
All systems should be tested under operating condition.
MHI BUSINESS
CONFIDENTIAL

Dry Barrel Hydrant:
Routine Maintenance
• Always ensure that the main supply valve and hydrant main valve are
completely closed before attempting to perform any hydrant maintenance.
• All AVK Dry barrel hydrants are factory tested and lubricated and require
minimum maintenance, but all fire hydrants should be inspected for
obvious damage, opened fully and flowed, at least once a year.
Warning:
All hydrants should be in the fully closed position while not in use. Any
partial opening will cause the drains to flush under full line pressure and
could wash out the drain bed and any restrains designed to hold the
hydrant in place.
MHI BUSINESS
CONFIDENTIAL

AVK Dry Barrel Hydrant:
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CONFIDENTIAL

• Foam System
• CO2 System
• FM-200 System
MHI BUSINESS
CONFIDENTIAL
OPERATION & CONTROL

Foam System Operation:
• Foam Compound (Low Expansion Foam) used for this application is
Extensid AFFF 3% Concentration with an expansion ratio of 6:1 to 10:1
dependent on type of equipment, water pressure and admixture.
• Water and foam are mixed together in a proportioning device. The mixture
is then conveyed under pressure to the foam production device where it is
turned to foam by means of entrained air.
• Extinguishing foam has different extinguishing effects which alone, or in
combination with others, ensure that the fire is extinguished quickly.
• The foam blanket separates the burning area from the surrounding air. It
also prevents any further oxygen reaching the extinguishing area.
• This particularly applies to liquid and solid material fires which have
extremely high surface temperatures. The water in the foam evaporates on
or immediately below the surface of the fire, thus extracting heat from the
burning material.
• When aqueous film forming foam (AFFF) is used, low viscosity film is
released from the foam. This film advances rapidly in front of the foam thus
giving it very good gliding and extinguishing properties.
MHI BUSINESS
CONFIDENTIAL
OPERATION & CONTROL

Foam System Operation (cont’d):
• The Foam System to the Foam Hydrants and Fuel Oil Tank protection is
manually activated by opening the hydrant valve and concerned main
isolation gate valve.
• Foam concentrate is automatically added to the fire water at the foam
station, if one of the systems is activated. The foam bladder tank supplies
the foam concentrate to the admixer, which adds the foam concentrate to
the water according to the water flow rate.
• The distribution pipework supplies the foam/water solution to the foam
generating equipment.
• Foam is generated at the foam making branch pipes of the tank protection
system and discharged into the protected tank by the foam pourers.
Foam/water jets for the foam hydrant generate and discharge foam.
• The system is manually operated. At manual operation mode of the foam
system, foam is generated and discharged onto the area affected, once
the operator has activated the foam system.
MHI BUSINESS
CONFIDENTIAL
OPERATION & CONTROL

Foam System Operation (cont’d):
• When the fire is extinguished and fire fighting can be stopped, the system
has to be turned off by closing the main gate valve at the deluge valve or
manifold.
• After fire fighting with a foam extinguishing system the pipework need to
be flushed with clear water.
• The pipework of the foam water hydrants and tank protection system are
filled up with the foam-water solution by opening the main gate valve
slowly.
MHI BUSINESS
CONFIDENTIAL
OPERATION & CONTROL

Foam Bladder Tank
MHI BUSINESS
CONFIDENTIAL
OPERATION & CONTROL

Foam Bladder Tank:
• The unit comprises a steel tank for storing the liquid concentrate and a
mixer which allows to mix the liquid with water in the chosen percentage.
• A bladder is installed inside the tank. During the operation of the unit, this
bladder transfers the pressure of the water that enters in the tank to the
concentrate, causing the concentrate to flow out.
The liquid concentrate, after passing through a calibrated diaphragm which
determines its percentage, is injected into the mixer, where it mixes with
the water.
MHI BUSINESS
CONFIDENTIAL

Foam System:
Periodic Maintenance Procedure:
• MONTHLY or AFTER EVERY EMERGENCY ACTIVATION :

Check the integrity of the bladder by opening the water drain valve (16): an
abundant presence of concentrate means that the bladder is perforated and
must be replaced.
• Do not perform welding on the tank body, otherwise the impermeable

bladder inside will be damaged.
MHI BUSINESS
CONFIDENTIAL

Foam System:
Periodic Maintenance Procedure (cont’d):
Foam Bladder Tank System with Concentrate Controller
INTERVAL
CHECK ITEM Quarter Half
Yearly yearly
Check the filling level of foam concentrate X
Check the foam concentrate tank regarding

leakage X
Check the condition of the Foam Bladder Tank

with Controller (piping, valves and instruments) X
Take 2 ltr. of foam concentrate out of tank and

5 years
send it to a laboratory for physical examination.
Check the condition of entire foam system (gate

valves, drain valves, piping & foam nozzles). X
MHI BUSINESS
CONFIDENTIAL

• Foam System
• CO2 System
• FM-200 System
MHI BUSINESS
CONFIDENTIAL
OPERATION & CONTROL

CO2 System:
• The pressure vessel serves the supply of CO2 to suppress fire by inerting.
The medium is supplied, within tight limits, at a constant pressure.
• The vessel serves as a store for very cold liquid carbon dioxide (CO2) at
approximately 19 bar / 1 bar and temperature of - 20oC / 2oC.
• Main component of the pressure vessel is an insulated low pressure
vessel which rests on a weighing system for measuring its contents.
• At the immersion pipe of the vessel a shut-off valve is installed which
connects to the fire extinguishing facility or pipeline.
• It also consists of a two-way valve and two safety valves, of which, in any
arbitrary position of the two-way valve, at least one safety valve is in
operation.
• To maintain a constant operating overpressure within tight limits, the
system is fitted with the cooling plant.
• The cooling plant consists of a semi-hermetical compressor, a air cooled
condenser, an axial flow fan and a coolant collector which are mounted
together on a base frame.
MHI BUSINESS
CONFIDENTIAL
OPERATION & CONTROL

CO2 System:
Low Pressure Tank
MHI BUSINESS
CONFIDENTIAL
OPERATION & CONTROL

CO2 System (cont’d):
• The cooling plant is controlled by an electrical control system. If the
operation overpressure increases due to warming up, the cooling plant
stays switched on, until, by cooling down the gaseous phase, the pressure
inside the vessel has decreased to the lower limit.
• As the temperature of the very cold CO2 in the container (-40oC to -16oC),
depending on the operating overpressure, is significantly lower than
ambient temperature, the CO2 must artificially be kept at this low
temperature. This is achieved by a cooling plant and the vessel insulation.
MHI BUSINESS
CONFIDENTIAL
OPERATION & CONTROL

CO2 System:
Cooling Plant
MHI BUSINESS
CONFIDENTIAL
OPERATION & CONTROL

CO2 System:
Cooling Plant
MHI BUSINESS
CONFIDENTIAL

CO2 System:
Half Yearly Check & Inspection Items:
EQUIPMENT CHECK, INSPECTION
CONTROL CUBICLE
Cooling plant Function, Switching-on/off pressure
High pressure alarm Function, adjustment
Low pressure alarm Function, adjustment
Motor protection relay Function, adjustment
Contactor Function
Fuses Function
Pressure and temperature indicator Function
COOLING PLANT
Cooling loop: Tightness, check for possible damages
Test run: 15 minutes, function
Coolant pressure: Suction side adjustments, Pressure side adjustments
Oil level check: On oil gauge glass, oil level between min. / max.
MHI BUSINESS
CONFIDENTIAL

CO2 System:
Half Yearly Check & Inspection Items (cont’d):
EQUIPMENT CHECK, INSPECTION
VALVES
Function, valve seat, tightness of the packing of the
Main shut-off valve
stuffing box
Ball valves Function, tightness
Two-way valve Function, tightness
Safety valve Function, tightness
Shut-off valve Function, tightness
Expansion valve Function, tightness
WEIGHING CELL
Visual check of display, connecting cables and load
Electronic scales
cells
MHI BUSINESS
CONFIDENTIAL
OPERATION & CONTROL

CO2 System:
Direct to Process CO2 Vaporizer
INITIAL START-UP INSTRUCTIONS
Note: This procedure should be performed by a qualified carbon dioxide
equipment technician only.
1. Set the low temperature shut off controller(s) at 5ºF (-15ºC).
2. Set the gas temperatures controller(s) at the desired gas discharge
temperature. Do not exceed 100 ºF (37.8 ºC)
3. Turn on the circuit breaker. Turn the ON/OFF switch on the side of the
control panel to the ON position.
4. Allow the vaporizer to cycle on and off one time. The only indication that
the vaporizer is working will be the sound of the electrical contactor(s)
clicking in when the vaporizer turns on and out when the vaporizer turns
off.
5. Open the liquid carbon dioxide supply isolation valve to establish carbon
dioxide flow.
6. Check the amp draw on the supply voltage wires for a balanced load.
MHI BUSINESS
CONFIDENTIAL
OPERATION & CONTROL

CO2 System:
Direct to Process CO2 Vaporizer (cont’d)
DAILY OPERATION
• Once the vaporizer has been installed and the Initial Start-Up Instructions
have been accomplished, it is ready for normal service.
• To remove the vaporizer from service, close the liquid carbon dioxide
supply isolation valve, relieve the line pressure, and turn the ON/OFF
switch on the side of the control panel to the OFF position.
MHI BUSINESS
CONFIDENTIAL
OPERATION & CONTROL

CO2 System:
Direct to Process CO2 Vaporizer
MHI BUSINESS
CONFIDENTIAL

CO2 System:
Direct to Process CO2 Vaporizer:
PROBLEM POSSIBLE CAUSE REMEDY
High Amperage 1. Improper supply (primary) voltage 1. Check voltage and correct
Low Amperage 1. Improper control (secondary) 1. Check voltage and correct
voltage
No control 1. Control circuit fuse blown 1. Replace
circuit power 2. Main circuit breaker tripped 2. Reset
3. Door open, cover removed 3. Be sure door is closed and cover
4. Door or cover safety switch(es) is in place
bad 4. Replace
Contactor(s) not 1. No output signal from gas 1. Verify control power at gas
pulling in temperature controller temperature controller - if power
2. High Temperature cut-outs tripped present, replace gas temperature
3. Broken or kinked gas temperature controller
thermocouple lead 2. Lower gas temperature controller
4. Bad contactor coil setting, allow unit to cool and
restart
3. Check and replace if needed
MHI BUSINESS
CONFIDENTIAL

CO2 System:
Direct to Process CO2 Vaporizer (cont’d):
PROBLEM POSSIBLE CAUSE REMEDY
Contactor(s) 1. Contactor(s) dirty or burned 1. Clean with contact cleaner or
hum replace
Unit shuts off 1. Low temperature controller(s) set 1. Set low temperature controller(s)
due to low gas too low or too high at 5ºF (-15ºC)
discharge 2. Carbon dioxide flow rate too high 2. Evaluate carbon dioxide flow rate
temperature 3. Broken or kinked low temperature and adjust as needed
thermocouple lead 3. Check and replace if needed
4. No output signal from low 4. Verify control power at low
temperature controller temperature controller(s) - if
5. Bad solenoid coil or solenoid power present, replace low
valve temperature controller(s)
MHI BUSINESS
CONFIDENTIAL

• Foam System
• CO2 System
• FM-200 System
MHI BUSINESS
CONFIDENTIAL

FM-200 System:
MHI BUSINESS
CONFIDENTIAL

FM-200 System:
Periodic Inspection
• This system shall be completed inspected annually – preferably every six
months – by component personnel using as approved schedule and
procedure.
• Visual inspection of all system components and cylinder pressure should
occur monthly.
• Cylinder weight and pressure must be inspected semi-annually per NFPA
2001.
• Any pilot hoses should be examined annually for damage. Any problem
should be corrected at once by component personnel.
• A cylinder continuously in service without having been discharged must
be given an external visual inspection every 5 years.
Detection and Actuation System

• The detectors should be checked (and cleaned, if necessary) to assure
that they are free of foreign substances.
MHI BUSINESS
CONFIDENTIAL

FM-200 System:
Detection and Actuation System (cont’d)
• If the detection system is supervised, the supervisory features should be
checked to determine that the detection system is in satisfactory condition.
Piping and Nozzles

• Piping should be examined for any evidence of corrosion. Nozzles should
be checked to determine that the orifices are clear and unobstructed; they
should be checked for proper position and orientation.
Auxiliary Equipment
• All auxiliary components such as door closures, dampers and air handling
shutdown equipment should be inspected to ensure that they are in proper
operating condition.
• Check that provisions have been made for prompt ventilation of a hazard
following a discharge.
MHI BUSINESS
CONFIDENTIAL

FM-200 System:
Storage mounting and Cylinder Assemblies
• Inspect the storage mounting for tightness, including wall mounting bolts
and other hardware, if included.
Electrical Components
• A functional operational test shall be performed on all electrical
components annually in accordance with the NFPA 72 National Fire Alarm
Code and Local Authority requirements.
General Maintenance
• The system should be maintained in full operating condition at all times. In
particular, the pressure and weight of the cylinders must be maintained.
• All hoses shall be examined annually for damage, and if visual inspection
shows any deficiency, the hoses must be replaced or tested as specified in
NFPA 2001.
MHI BUSINESS
CONFIDENTIAL

FM-200 System:
Cylinder Storage Pressure
• The pressure in the storage container(s) should be noted on a monthly
basis.
• If the temperature in the storage container is about 21oC, the pressure
should be 2482 kPa. If the temperature is lower or higher, the pressure will
be somewhat lower or higher in accordance with the following table.
• If the pressure shows a loss between monthly readings, the container
should be inspected for possible leaks using soap suds or some other
sensitive method of leak detection.
• If the loss in the pressure is more than 10%, the cylinder must be refilled or
replaced.
MHI BUSINESS
CONFIDENTIAL

FM-200 System:
Cylinder Storage Pressure (cont’d)
Isometrics for FM-200 at Fill Density 1121 kg/m3
Superimposed with Nitrogen to 2482 kPa at 21oC
Temperature Gauge Pressure
(oC) (kPa)
0.0 1987
4.4 2091
9.9 2215
15.6 2346
21.0 2482
26.8 2629
32.1 2774
37.7 2933
43.0 3099
49.0 3278
54.0 3464
MHI BUSINESS
CONFIDENTIAL

FM-200 System:
Cylinder Content (Weight) Check
• At least semi-annually, the agent quantity and pressure of refillable
container shall be checked. A container shall be refilled or replaced when it
shows a loss in agent quantity of more than 5% or a loss in pressure
(adjusted) of more than 10%.
• The cylinder contents can be checked by weighing using a standard
platform scale having suitable capacity. When weighing it will be
necessary to remove the cylinders restraining strap from the mounting
assembly.
IMPORTANT:
Before any cylinder restraining straps loosened or discharge piping disconnected, do the
following:
- Disconnect the solenoid pilot valve assembly or pressure gauge assembly and manual
pneumatic actuator from cylinder(s).
- Disconnect the flexible connector from the top of the cylinder(s).
- Then disconnect the discharge tube at the cylinder valve connection.
- The valve anti-recoil should be attached to the cylinder valve discharge outlet.
- HANDLE CYLINDERS WITH EXTREME CARE!
MHI BUSINESS
CONFIDENTIAL

FM-200 System:
Complete Cylinder Recharge
• If more than 5 years elapsed since the date of the last test and inspection,
the cylinder shall not be recharged without first restarting.
• This retest must include an external and internal visual inspection in
accordance with Code of Federal Regulation, Title 49, Section
173.34(e)(10) and NFPA 2001.
Hose Test
• All system hose shall be examined annually for damage, if visual
examination shows any deficiency the hoses shall be immediately
replaced or tested as specified in NFPA 2001.
• All hoses shall be tested every 5 years.
Refilling or Replacing of Cylinders

• This shall be performed by authorized distributor.
MHI BUSINESS
CONFIDENTIAL

• Foam System
• CO2 System
• FM-200 System
MHI BUSINESS
CONFIDENTIAL
OPERATION & CONTROL

Portable Fire Extinguishers:
MHI BUSINESS
CONFIDENTIAL
OPERATION & CONTROL

MHI BUSINESS
CONFIDENTIAL

Maintenance of Fire Extinguishers
Quarterly Check:
1. Check the safety pin in unplug
2. Check the pressure gauge is on normal condition
3. Check for external damage or corrosion
MHI BUSINESS
CONFIDENTIAL
THANK YOU
VERY MUCH !
MHI BUSINESS
CONFIDENTIAL

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PAITON Ⅲ EXPANSION PROJECT

CONTENTS ： G-10 Fire Fighting System

MITSUBISHI HEAVY INDUSTRIES, LTD.

Operation & Control

OPERATION & CONTROL

OPERATION & CONTROL

Operation & Control

OPERATION & CONTROL

OPERATION & CONTROL

OPERATION & CONTROL

OPERATION & CONTROL

Pump Name Quantity Type Capacity Diff. Head

Motor Driven Horizontal, 2000 GPM

Diesel Engine Driven Vertical 4000 GPM

Vertical, 32.4 GPM

Motor Driven Booster Horizontal, 158 GPM

Operation & Control

OPERATION & CONTROL

OPERATION & CONTROL

Operation & Control

OPERATION & CONTROL

OPERATION & CONTROL

OPERATION & CONTROL

OPERATION & CONTROL

OPERATION & CONTROL

OPERATION & CONTROL

OPERATION & CONTROL

Operation & Control

OPERATION & CONTROL

OPERATION & CONTROL

OPERATION & CONTROL

OPERATION & CONTROL

OPERATION & CONTROL

Maintenance & Troubleshooting

• Fire Water Pumps & Motors

MAINTENANCE & TROUBLESHOOTING

MAINTENANCE & TROUBLESHOOTING

MAINTENANCE & TROUBLESHOOTING

MAINTENANCE & TROUBLESHOOTING

Cracked foundation Replace foundation.

Worn ball bearings Replace bearings. Check lubricants for proper

MAINTENANCE & TROUBLESHOOTING

MAINTENANCE & TROUBLESHOOTING

MAINTENANCE & TROUBLESHOOTING

MAINTENANCE & TROUBLESHOOTING

Rotor out of balance.

dirty oil or contaminated.

lower than rating.

Air or gas in liquid.

Excessive noise from

Pump bearings run

hotter than normal.

Motor runs hotter

MAINTENANCE & TROUBLESHOOTING

Rotor end ring (or end turns) Yearly Yearly

Stator core (with rotor removed) Every 5 years Every 5 years

Brushes and collector rings Quarterly Monthly