PROJECT REPORT ON FIRE

SAFETY SYSTEMS AT
OERLIKON GRAZIANO

ADITYA SINHA
(ROLL NO. 02, SESSION 2015-16)

POST DIPLOMA IN INDUSTRIAL SAFETY

REGIONAL LABOUR INSTITUTE, FARIDABAD
 CERTIFICATION

This is to certify that Aditya Sinha (Roll No. 02), student of “POST
DIPLOMA IN INDUSTRIAL SAFETY ” Year 2015-2016 being conducted
by “Board of Technical Education Haryana” at Regional Labour Institute,
Faridabad (Haryana) has done his project work on “ Fire Safety System at
Oerlikon Graziano” under my guidance.

Date: M. R. Rajput
Director In-charge
Regional Labour Institute
Faridabad, Haryana
 TABLE OF CONTENTS

Chapter Title Page No.

Introduction 1

1 Company Profile 2

Environmental, Health and Safety Policy (HSE) 10

2 Literature Review 12

Spreading of Fire 13

Phases of Burning 14

3 Sources of Fire Hazard 15

Identify Sources Of Fuel 15

Identify Sources Of Oxygen 16

Identification of Fire Hazard within the company 17

4 Fire Detection Systems 18

Smoke Detectors 18

Heat Detectors 19

Sounders or fire alarm devices 19

Call Stations 20

Fire Suppression & Protection Inventory 22

Causes of Fires 23

5 Fire Protection Systems 25

26
Portable Fire Extinguisher
 30
Sprinkler System

Carbon Dioxide Flooding System 34

Fire Hydrants & Spray Systems 36

Fire water reservoir details 39

6 Inspection & Maintenance 40

Maintenance Schedule of Medium Velocity Water Spray
40
system
Maintenance Chart of CO2 Fire Extinguisher 42

Maintenance Chart of Cartridge Type Fire Extinguisher 43

Maintenance Chart of CO2 Flooding System 44

Maintenance Chart for Smoke Alarm 45

7 Conclusion & Recommendations 46

References 47

Annexure 1 48

Annexure 2 54

Annexure 3 56

Annexure 4 57
 Introduction

The process chain in a manufacturing plant is designed for maximum

efficiency. If one production stage fails, the business stops. Optimal fire protection
therefore calls for specialist components for each area of the plant in order to keep
downtimes to an absolute minimum. The risk of fire is high: welding machines,
control rooms and hydraulic rooms, oil cellars, cable channels, Heat Treatment
Furnaces etc. Production machines are a particular fire hazard because of flammable
liquids such as oil, deposits and hot machine parts that may be ignited by electrical
ignition sources. Plant-dependent fire loads such as synthetics, ducts and oil reserves
increase the risk. Investments in fire protection are crucial.

The objective of this project is to analyze, understand & improve the fire safety
system in the Greater Noida plant of Oerlikon Graziano.

1
Chapter 1
Company Profile

Oerlikon Graziano is located in Greater Noida on 15 acres of land (60,000 sqm)

having 32,860 sqm covered area with fully capitalized power (6875 KVA PLC
controlled generators) and is specialized in production of gears, shafts, synchronizer
assemblies, crown wheel & pinion, axles and transaxle assemblies for agricultural
tractors, construction equipment, commercial vehicles, utility vehicles and other off-
highway applications, under the Oerlikon Graziano brand.

In 2012 this facility had expanded its covered area to offer its customers latest
technologies and high quality products such as

• Transaxle for Golf Utility Vehicles

• Transaxle for Customized Applications (CVT technology)

2
 • Axles for Construction Equipment

• Precision gears and shafts crown wheels and pinions: World’s largest supplier of
precision gears, the specialist ring gear supplier for final reduction components
and shafts for the Agricultural and Off-Highway vehicle markets, active in 11
plants in Italy, India, China, Czech Republic and USA.
• Gears & Shafts

3
• Synchronizers:
o Almost 70% of all Agricultural Vehicles in production today utilize their
synchronizers and/or our power shift clutch technology.
o currently produce more than 800.000 synchronizers per year for
passenger cars, trucks, tractors and construction equipment.

o They can provide friction materials to suit the specific requirements of

their Customers whether it is bronze, molybdenum, sintered bronze or
even carbon for the more arduous applications.
o They have extensive range of synchronizers from 62 to 138 mm diameter,
in ether single, double and even triple cone solutions.

4
 o Their R&D capability is world renowned within the industry and provides
all necessary design and test capabilities. These include :
§ Design: preliminary study, FEM analysis, ITI-SIM simulations
§ Specific test benches for: friction materials, synchronizer unit,
complete gearbox, vehicle tests, shift ability, and low temperature
testing
o Constantly developing new products to meet the ever changing and
challenging demands of their customers
§ A Triple cone D.90/95/100 with low module teeth to prevent
double bump and to improve shift comfort under extreme loads
§ Modular design T/C D. 105/113/119 for heavy applications
• Power shift Units: design and manufacturing the power shift clutches using the
most advanced manufacturing techniques including EB and Laser welding. The
technologies available for producing the clutch housing are flow forming, grob
rolling and their own fabricated broached design.

5
• Crown Wheels & Pinions - Differential Gears: the choice of Gleason, Oerlikon,
and Klingelnberg (Palloid) systems, dependent on the customer’s individual
applications and or specific needs. In support of this, we operate the very latest
software with the capability of close looping the Central computer, to the CNC
Blade grinder, to the CNC Cutting Generator, to the CNC Measuring Machine
and finally back to the central computer. This allows us to almost instantaneously
determining our capability to meet the initial design intent and if necessary
model and define any changes that may be necessary. We also have all relevant
Gleason technology available to cut straight gears for differential type
applications in both Coniflex and Revacycle methods.

6
The main Customers of Oerlikon Graziano are Alfa Romeo, Aston Martin, Audi,
Automobili Lamborghini, BMW, Ferrari, Fiat, Maserati, McLaren, Triumph,
Volkswagen.

7
Gear Manufacturing Operations

Overview of Heat Treatment Process

Types of Furnaces in use within the plant:

• SQF Furnace (Shield Quench Furnace)
• Electric and Gas furnaces
• Rotary Furnace
• CGCF (Controlled Gas Carburizing Furnace)

8
RECEIPT OF PUNCHING
SOFT FIXTURING
MATERIAL

PREWASHING
PRESS CARBURIZING AND
QUENCHING PRE-HEATING

POST TEMPERING MET. LAB

WASHING INSPECTION

PHOSPHATING DEBURRING SHOT

BLASTING

RELEASED
FOR NEXT
CYCLE

9
 Environmental, Health and Safety Policy (HSE)

Considering the nature and the extent of its health and safety hazards and of its impact
on the environment, Corporate Governance has wanted, organized and defined a
structure responsible for the implementation and verification of the system for the
management of health and the environment, making the necessary resources available.

The pursuit of the objectives and of the improvement goals will happen through:
• the protection of the workers’ health and safety, guaranteeing conditions of
physical, mental and social well-being;
• the constant monitoring of the environmental health and safety performance
connected to the working activities;
• the assessment of hazards and of environmental impact in the planning phase of
new activities, processes, products, systems and services;
• the training and accountability of the staff and the increased awareness of
suppliers and collaborators aiming at making people more mindful about the
environmental, health and safety aspects connected to their activities;
• the systematic communication about environmental and health performances;
• a continuous dialogue with the internal and external parties involved, increased
awareness and involvement of the workers and suppliers about the themes
connected to health, safety and the environment.

Such objectives are developed in the “Plan for the improvement of health, safety and
the environment” that represents the main management tool to translate and enact the
principles mentioned in the policy.

Oerlikon Graziano is committed to spreading such Policy to all the staff who works for
the organization or on its behalf, and to make it available to the public.
Corporate Governance is committed to reassessing the contents of the Policy every year
to guarantee its adequacy.

10
11
Chapter 2
Literature Review

Fire may be defined as a rapid oxidation of

substance accompanied by the evolution of energy in the
form of heat and light. It is an exothermic chemical
reaction. The heat evolved help in continuing and further
enhancing this reaction this phenomenon is commonly
called combustion or burning

Four basic things necessary for a fire are

1. Fuel :- Solid, Liquid or Gas
2. Air or Oxygen :- Oxygen reacts with fuel and evolves energy.
3. Heat or source of ignition :- Chemical heat energy , mechanical heat energy,
electrical, heat energy, nuclear heat energy, spontaneous ignition, open flame etc. act as
source of ignition.
4. Chain Reaction:- For fire to occur un inhibited chain reaction as required

Thus to extinguish any fire we have to remove any one of the four constituents
of the fire. So any fire can be extinguished by stopping fuel supply (starvation) or by
excluding fuel from air or oxygen (smothering) which can be accomplished by creating
a barrier between the burning fuel and the external air or oxygen / diluting oxygen or
by removing heat (cooling) or inhibiting chain reaction.

Fire Load is the heat generated by the combustible material within the building. It is
the product of mass of materials and its heat of combustion or calorific value

Fire load density : it is the heat per unit area of floor which can be generated.

12
 Type of fire Fire load Types of
load density Occupancies
Low 12.5 Dwelling & offices
Medium 12.5-25 Factories
High >25 Ware house

Fire Resistance Rating — The time that a material or construction will withstand the
standard fire exposure as determined by fire test done in accordance with the standard
methods of fire tests of materials/structures.

Automatic Fire Detection and Alarm System — Fire alarm system comprising
components for automatically detecting a fire, initiating an alarm of fire and initiating
other actions as appropriate.

Automatic Sprinkler System — A system of water pipes fitted with sprinkler heads at
suitable intervals and heights and designed to actuate automatically, control and
extinguish a fire by the discharge of water.

Combustible Material — The material which either bums itself or adds heat to a fire.
Fire Door — A fire-resistive door approved for openings in fire separation.

Fire Exit — Away out leading to an escape route having panic bar hardware provided
on the door.

Spreading Of Fire
Conduction:- It is important particularly in allowing heat to pass through a solid barrier
and ignite material on the other side.

Convection:- The hot products of combustion rising from a fire typically have a temp
range 800-1200 degrees and a density quarter that of air. On open plant much of the
heat is dissipated into the atmosphere but in buildings it is transferred to the ceiling.

13
Radiation:- It is the main mode of heat transfer although it is usually accounts for a
smaller proportion of the heat issuing from the fire radiated heat is transferred directly
to nearby objects.

Phases of Burning

1. Initial stage phase

-First stage burning.
-Emission of heat and combustible gases.

2. Free burning phase

-Second stage of burning
- Temperature goes up to 700 degrees
- fire spreads all over the area.

3. Smoldering phase
-complete combustion stage
-Flames normally disappeared
-Entire area / building found occupied with combustion products

4. Flash Over:
-Temperature in the surroundings obtains extremely.
-Possibility of re-ignition due to auto-ignition.

14
Chapter 3
Sources of Fire Hazards

Potential ignition sources are those where sources of heat could get hot enough to
ignite material found in the premises. These sources could include:

• Flames, heater, furnace.

• Hot surface – welding, cutting, grinding.
• Hot – surface – hot process equipment distressed machinery.
• Hot particles.
• Friction and impacts.
• Chemical energy.
• Hot materials and gases.
• Reactive, unstable and pyrophoric materials.
• Engines.
• Vehicles
• Lightning.
• Radio frequency emissions.
• Smoking.
• Arson and sabotage.
• Self heating.
• Static electricity.
• Electrical equipment.
• Auto ignition.
Indications of near misses such as scorch marks, discoloured or charred electrical plugs
and sockets, cigarette burns etc, can be used to identify hazards.

Identify Sources Of Fuel

Material which will burn reasonably easily and is in enough quantity to provide fuel
for a fire or cause it to spread to another fuel source should be considered. This applies

15
to contents, fixtures and fittings and also to structure and materials used to construct or
line walls and ceilings such as polystyrene or tiles. These fuels might contribute to the
spread of fire and should be identified. Factories and storage premises are likely to
contain significant quantities of fuel. Some of the most common ‘fuels’ found are:
• Textiles,
• soft furnishings and clothing;
• Flammable liquids and solvents, such as paraffin, white spirit, methylated spirit,
alcohol, cooking oils, some solvents, paints and adhesives;
• Flammable chemicals, such as certain cleaning products and photocopier
chemicals that use hydrocarbon solvents;
• Packaging materials, pallets and racking;
• Combustible core of insulated panels;
• Stationery and advertising material;
• Plastics, cellular foams and rubber, such as upholstered furniture and tyres;
• Waste material, particularly when finely divided such as shredded paper, wood
• shavings, off cuts, and dust;
• Flammable gases such as liquefied petroleum gas (LPG) and acetylene;
• Hydrogen produced during battery charging;
• Powdered materials or dusts (including materials which are not normally
considered a fuel when in an undivided state but where as a dust they may be
prone to dust explosions. Examples are flour, animal feed and some metals); and
• Vehicle and plant equipment fuels.

Identify Sources Of Oxygen

The main source of oxygen for a fire is in the air around us. Air supply generally
falls into one of two categories: natural air flow through doors, windows and other
openings; or mechanical air conditioning systems and air handling systems. High
Concentration of oxygen can cause material to burn extremely rapidly and some
materials which are not normally considered combustible, can burn in an enriched
oxygen atmosphere. Oxygen is dangerous when in contact with grease or oil.

16
 Additional sources of oxygen can sometimes be found in materials used or stored
in premises such as:
• Some chemicals (oxidising materials), which can provide a fire with additional
oxygen and so assist it to burn, or
• Oxygen supplies from cylinder storage.

Identification of Fire Hazard within the company

Area of Risk Possible Hazard

Leakage from tank

Oxygen Storage Tank Fire
Explosion
Leakage from tank
Propane Storage Tank Fire
Explosion
Sparks from machines could be a possible source of
Shop Floor ignition
Oily Rags may spontaneously combust
Flammable Material (Wooden boxes/pallets/packing
Warehouse material)
Spillage of fuel from transport vehicles
Overheating
Server Room
Electrical Malfunction

Solar Array Battery Overheating

Room Electrical Malfunction
Assembly Point Only one Assembly point

17
Chapter 4
Fire Detection Systems

Fire detection ranges from

building-wide alarm systems to single-
unit battery-operated systems. There are
several different forms of fire alarms
which include smoke alarms, Call
stations, heat detectors, flow switches,
and audible and visual alarms. Smoke
alarms can either be stand-alone devices
or connected into the building’s fire alarm system.
A Call station is a device located on the wall that is used to set off the building’s
fire alarm.
Heat detectors detect either a certain temperature or rate of rising temperature.
Flow switches are built into a sprinkler system and when the water inside the pipes
starts to flow, trigger an alarm. Audible and visual alarms may use horns, audio
introductions, or flashing lights to notify people to exit the building.

Smoke Detectors: moke detectors

are provided in DG Room and Control Room.
On actuation it gives audio visual alarm in the
Fire Station and repeated in Control Room
Smoke Detectors or sensors, are
sensitive to smoke in the surrounding
atmosphere. Photoelectric/optical smoke
sensors use a Light Emitting Diode (LED) and
a photodiode sensing element. Smoke
particles entering the chamber cause the LED
light to scatter, thus triggering an alarm

18
status. Ionization smoke detectors use an ionization chamber. Smoke particles entering
the chamber attach themselves to the ions, impeding the generated current flow and
causing the alarm to trigger.

Heat Detectors: Heat detectors, detect changes in ambient temperature, and

send an alarm state to the CIE. Rate of rise detectors which measure the speed with
which the air temperature rises and fixed temperature detectors which react when a set
temperature is reached

Multi-Criteria Detectors: These detectors are a combination of smoke and

heat sensors and can be addressable or conventional, the difference being their level of
communication to the main fire control panel.

Sounders or fire alarm devices: Sounders or fire alarm devices are the fire
detection and alarm system’s means for alerting the occupants of a building to potential
or imminent danger from
fire. Sounders vary in size and shape
and the sounder output varies in level,
frequency range and temporal pattern,
but all must comply with the
requirements of the same product
standard. There are two types of
sounder – outdoor or indoor use. The
main difference between the two being
the level of protection against the
ingress of water or foreign bodies by
the use of rubber seals, exterior housing design and the severity level of environmental
tests applied. The majority of sounders are designed for connection to fire alarm system
control panels and are usually rated to operate from a 24V supply.

19
 Call Stations/Points: Manual call point and smoke detectors are provided in the
shop floor & other areas of the company, which on actuation gives audio – visual alarm
in the Control room, indicating exact location of smoke detector actuated.
Manual fire alarm is activated by a call point which then sounds the evacuation
alarm for the relevant building or zone. Most call points are operated by breaking a
frangible glass element which operates a micro-switch inside the call point. Manual fire
alarm activation requires human intervention, as distinct from automatic fire alarm
activation such as that provided through the use of heat detectors and smoke detectors.
It is possible for call points to be used in conjunction with automatic detection as part
of an overall fire detection and alarm system. Systems in completed buildings tend to
be wired in and to include a control panel.

Call points are

located on all final exits,
all storey exits i.e.
entrances to stairwells
and call point units are be
located near to any high
risks or special hazards.
Call points should
be distributed in a
building so that no one
need travel any more
than 45 metres to reach
their nearest call
point. This distance is
measured against the actual route a person would follow taking into account locations
of walls, partitions and fixings. For high risk areas and special hazards as mentioned
above a person should have to travel no more than 25 metres to reach their nearest
manual call point taking into account fixtures and fittings.

20
Fire Alarm System

21
Fire Suppression & Protection Inventory

Fire Alarm Portable

Area Of Panel Smoke Heat Call Audible Hydrant Sprinkler CO2
System Fire
Risk Model Detectors Detectors Stations System System System Flooding
Manufacture Extinguisher
Oxygen
Storage Simplex 4009 5 5 3 YES YES NO 8 NO
Tank
Propane
Storage Simplex 4009 5 5 3 YES YES NO 8 NO
Tank
Shop Floor Simplex 4009 75 50 22 YES NO YES 27 NO

Warehouse Simplex 4009 18 10 7 YES NO YES 10 NO

Server
Simplex 4100U 2 5 0 YES NO NO 3 YES
Room
Solar
Array
Simplex 4100U 2 3 0 YES NO NO 2 YES
Battery
Room

22
 Causes of Fires:

Using previous reports accident data was collected and analyzed about fires from
2013 through 2014. The company fires and resulting injuries reported based on heat
source and equipment involved

Number of Percentage of All

S.No. Causes of Fires
Fires Fires
1 Welding Operation 3 3.57
2 Clipping Section Sparks 17 20.24
3 Quenching Oil Ignition 2 2.38
4 Electrical Malfunction 21 25.00
5 Heating Equipment 5 5.95
6 Smoking Materials 29 34.52
7 All Other 7 8.33
Total 84 100

Welding Operation:
• 2 Incidents of worker uniform catching fire
• 1 incident of wooden box on storage rack smoldering

Clipping Section Sparks

• 8 Incidents of oily firer dent separators igniting
• 9 Incidents of cleaning rags igniting

Quenching Oil Ignition

At the heat-treatment section turned gear from furnace at 880 °C was introduced
into the quenching oil bath by a fork for heat treatment. The treated gear was left for
more than the stated time, the quenching oil in the bath was heated, and a fire occurred.

23
Electrical Malfunction
• 3 incidents of Sparks & smoke in the server room triggered the smoke alarm
• 1 incidents of malfunctioning battery in the Solar Battery room
• Short Circuits

Heating Equipment:
Flame Door malfunction in conditioning zone of CGCF

Smoking Materials:
Improper disposal of cigarette ends into rag disposal bins resulting in smoldering, or
discarding into packing crates containing RPO (rust prevention oil).

Others
Burning of wood by local residents outside the factory compound during winter season
is considered hazardous has to be extinguished .

24
Chapter 5
Fire Protection Systems

Following elements at the factory are part of the Active Protection System:
• Portable fire extinguishers.
• Sprinklers and Water spray.
• Fire water supply.
• Hydrants and Monitors.
• Foam Injection for storage tanks (Static foam system)
• Fire alarm system.
• Heat Detector
• Smoke detectors.
• Trailer mounted foam monitor.

Following elements at the factory are part of the Passive Protection System:

• Stability :- It refers to the load bearing capacity of an element of

compartment without fall during fire condition.
• Integrity :- It refers to the ability of an element of a compartment to
withstand the fire conditions without cracking which may otherwise allow
the smoke or flame to pass through the cracks spread beyond the
compartment.
• Insulation :- Means ability of an element of compartment to prevent the
transfer of heat from one side to the other.
Methods of Extinguishing Fire:
• Eliminating the combustible fuel (Starvation): If unburned fuel is
removed from the fire by physical or mechanical means the combustion
will cease. For Eg. The best method of handling of gas fire is to stop the
flow of a gas by closing of the main valve for shutting of the supply.

25
 • Cutting off the oxygen supply (Smothering): If the oxygen is removed or
prevented from reaching the combustible material by blanketing or
diluted by an inert gas or dispersion in it of a non combustible power the
combustion will cease.
• Cooling to point below ignition temp (Cooling): It is removed by cooling
with water then combustion will cease. Cooling of the burning material
reduces the temperature of the material to below it’s ignition temperature
and thus the fire is completely extinguished.
• Inhibition (breaking) of chain reaction.

Portable Fire Extinguisher: Several portable fire extinguishers are provided

at strategic location of the plant as required under NFPA – 10 guidelines. The proper
use of portable fire extinguishers can extinguish many fires while they are still small.
These portable fire extinguishers are an important part of an overall fire safety program.
The successful use of portable fire extinguishers depends on the following:

• the portable fire extinguishers are properly located and in working order.
• the portable fire extinguishers are of the correct type.
• the fire is discovered while still small enough for use of the portable fire
extinguishers to be effective.
• the fire is discovered by persons who are ready, willing, and able to use
the portable fire extinguishers.

Class Description Suitable fire Nos. Installed

of Extinguisher
fire
Fire involving solid combustible 20
A materials of organic nature such as Water
wood, rubber, plastic etc. where the

26
 cooling effect of water is essential
for extinguish of fire.

Fires involving flammable liquids or Dry chemical 17

B liquefiable solids or the like where a powder, CO2,
blanketing effect is essential Mechanical
Foam
C Fires involving flammable gases, Dry chemical 12
compressed gases, liquefied gases of powder, CO2
flammable nature
Fires involving combustible metal Special Dry 9
such as Magnesium, aluminum, chemical
D zinc, sodium, potassium etc. when powders/ like
the burning metals are reactive to turnery eutectic
water and water containing agents chloride, Na-X,
and in certain cases carbon dioxide Metal-X
and ordinary dry powder. These
fires require special media and
techniques to extinguish.

27
Water is used in most of the Fire fighting systems as it has many advantages:
• It is the universal solvent –hence water dissolves ash etc and reaches seat
of fire.
• Specific heat -418.2 KJ/kg and latest heat vaporization is 2260 KJ/kg –
highest cooling capacity.
• Expansion ratio :1650 disperse oxygen on vaporization.
• Relatively stable liquid under atmospheric condition.
• High molecular stability up to 1650 degrees (does not dissociates on when
applied on normal fires)
• High surface tension = 72 dynes / cm (formation of jet)
• Less change in viscosity with atmospheric conditions make it easy to
flow.
• High density ensures sufficient mass goes on fire.
But in some scenarios water is not suitable as an extinguishing agent. The
limitation of water as an extinguishing agent:-
• Water freezes at 0 degrees

28
 • Restricts penetrations and wetting various combustible materials because
of high surface tension.
• Water turns off readily because low viscosity
• High friction loss
• Unsuitable for extinguishing electrical fires
• Due to high surface tension does not penetrate in porous substances

In these situations other materials are used.

Foam: Water can not be used on hydrocarbon fires due to its high density. To overcome
this problem foam is used to extinguish hydrocarbon fires (class B fires)
• Water + foam concentrate + air = foam
• It is a homogeneous mass of tiny air / gas filled in water bubbles of low
specific gravity
• It extinguishes the fire by
Ø Cooling effect
Ø Smothering effect
Ø Starvation effect
• Used for extinguishment of bulk and spill fire of flammable liquids(Class
B)
Dry Chemical Powder :- Used for Class C Fires

Sodium bi carbonate Alkali DCP

2NaHCO3 + Heat à Co2 + Na2CO3+H2O
Na2CO3 + Heat à Co2 + Na2O
Na2O + H2O (from combustion) à 2NaOH
NaOH + H- à Na + H2O
NaOH + OH- à Na + H2O

Carbon Dioxide (CO2):

• Its vapor density is 1.5 (heavier than air)

29
 • It expands 450 times
• It is non-combustible gas and clean media
• It is non – conducting media
• Extinguishes fire by
Ø Smothering effect
Ø Cooling
• It is suitable for Class B, Class C fires
• It is suitable for electrical fire

Sprinkler System: A sprinkler system consists of a water supply and one or

more sprinkler installations; each installation consists of a set of installation control
valves and a pipe array fitted with sprinkler heads. The sprinkler heads are fitted at
specified locations at the roof or ceiling, and where necessary between racks, below
shelves, inside ovens or stoves or below obstructions. The main elements of a typical
installation is shown:

30
 A sprinkler has two functions to perform. It must first detect a fire, and must then
provide an adequate distribution of water to control or extinguish it. Each function is
performed separately and one is independent of the other except insofar as early
detection makes extinction easier because the fire has not grown large. The classic use
of the sprinkler is in the hot gas layer which forms beneath the ceiling of an enclosure
in which a fire is developing.

31
 The sprinklers operate at pre-determined temperatures to discharge water over
the affected part of the area below, the flow of water through the alarm valve initiating
a fire alarm. The operating temperature is generally selected to suit ambient temperature
conditions. Only sprinklers in the vicinity of the fire, those which become sufficiently
heated, operate. The provision of sprinkler system entirely does not negate the need for
other means of fighting fires and it is important to consider the fire precautions in the
premises as a whole.

Water for the sprinkler system is stored in easily accessible surface &
underground reservoir. For moderate hazard in the company, exclusive water storage is
200 m3 . Water is discharged at a flow rate of 1800 LPM for adequate fire control.

32
Sprinkler System in Warehouse

33
Carbon Dioxide Flooding System:
CO2 Fire Suppression System uses carbon dioxide which is very economic and can be
used for total flooding system when an area is attacked by intense fire. The CO2 gas has
higher ratio of expansion which facilitates rapid discharge and allows for three
dimensional penetration of the entire hazard area quickly.

CO2 protects the area and instantly stops the intensity of fire by reducing the content of
oxygen. With no residue left behind, the CO2

34
Fire Suppression System does not damage any sensitive electronic machine. The
device can protect a large area which is attacked by fire hazards. Fire suppression
systems for server rooms and data centers are essential to the server room itself.

35
Fire Hydrants & Spray Systems
Medium velocity water spray systems (MVWSS) have been installed for
all bulk storage tanks, also for tanker loading station. The design of spray system
has been based on water demand rate of 10.2 LPM/m2 of tank surface.

36
 A typical spray system for the storage tanks consists of a taping form the
main fire hydrant line with a sluice valve, Y- type strainer, a deluge valve
followed by another sluice valves. GI piping downstream of the valve branched
off at required height into a ring and a branch extending to top of tank.
Adequate number of spray nozzles mounted on the GI piping and located
to give the desired spray pattern and wetting the protected surface area of the tank
with the required flow rate of 10.2 LPM/m2 of tank surface
Fire water header is always maintained under pressure with the help of
pilot jockey pump through out the large network of underground hydrant line,
feeding a number of hydrants, monitors, MVWSS, water curtain and foam
pouring system at different locations in the plant. A total number of 31 single
hydrants (external) are located above ground at critical locations of the plant each
on stand post.
In addition to this 18 single hydrants (internal) have been provided at
higher elevations of the main plant.

37
4 monitors are installed around the
main plant and another 4 monitors are
installed around the Propane storage
area, each of these monitors has 38
mm dia outlet.
A total 10 hose stations (containing
five hoses, two carboys – 40 liters
Foam pouring (Injection) for storage tanks (Static
each, two foam branches and three foam system)

38
water type branches) and 30 hose boxes (containing two hoses and one TP
branch) have been installed.

A 3% AFFF type foam system is provided for protection of the insulated storage.
A FRP line MS foam tank of 1000 liters capacity is provided near the storage
tank area.

Fire water reservoir details:

Capacity:- 4538 m3

Fire water supply (underground network). Consist of following water pumps

• Electric motor driven pump : 1 no, 210 m3/hrs capacity, 80 MLC head
• Diesel motor driven pump : 2 no, 210 m3/hrs capacity, 80 MLC head
• Electric motor driven jockey pump : 1 no, 20 m3/hrs capacity, 80 MLC head
• Electric motor driven jockey pump : 1 no, 5.8 m3/hrs capacity, 80 MLC head

39
Chapter 6
Inspection & Maintenance

Maintenance Schedule of Medium Velocity Water Spray system

Item Activity Time

Reservoir Level checking clearing Weekly
Running test Daily 5 min
Test Flow Annually

Pump Lubrication Quarterly

GI & packing Weekly
Once in two
Over haul
years
Running test Daily 5 min
Lubrication quarterly
Battery weekly
Engine
Load Test annually
once in two
Over haul
years
Fuel Tank Check Daily
Lubrication weekly
Motor
Starter Contact Checking weekly
once in two
Flushing
Main Piping years
Guage Pressure Daily
Operation monthly
Sluice Vales Gland Packing monthly
Lubrication Quarterly
Operation weekly
Deluge Valves Alarm Check weekly
over haul annually

40
 Cleaning quarterly
Cleaning Quarterly
Sprayer
Flow Test quarterly
Detectors Performance Six Monthly

Spray Performance Quarterly

Installation Physical check of pipes monthly
Pressure Gauge Calibration Annually

41
Maintenance Chart of CO2 Fire Extinguisher

42
Maintenance Chart of Cartridge Type Fire Extinguisher

43
Maintenance Chart of CO2 Flooding System

44
Maintenance Chart for Smoke Alarm

45
Chapter 7
Conclusion & Recommendations

From the fire accident data analysis we observe that all required safety measures are in
place. Some recommendations were made as follows:
• Welding Aprons suggested to protect workers. Training for use and motivation
techniques must be used to promote usage of new PPE.
• Re-Train & Educate welding section on identification of possible hazards in the
area, and to remove them from the vicinity before starting welding operation
• Clipping machine was initially enclosed on two sides, preventing injury from
chips, but not sparks released from the back of the machine. Full enclosure of
transparent fiber material suggested to control wayward sparks
• Current flooding system uses CO2, which is a polluting agent. For environmental
considerations suggested to move system to inert gas flooding system.
• Training & Education to raise awareness against smoking within the company
premises as it can have dire consequences, both in terms of fire hazard & direct
health risks
• Only one assembly point established within premises. Suggested at least a total
of two assembly points, in case a fire breaks out near the assembly point.

46
 References

1. National Fire Protection Association: NFPA 1 Uniform Fire Code, 2003

2. National Building Code of India: NBC Chapter 4, 2005, Bureau of Indian
Standards
3. Safety Training Manual & Guidelines of Oerlikon Graziano, 2014
4. Records & Data from Oerlikon Graziano, 2014
5. Photographs from Oerlikon Graziano
6. Images for representation from Google

47
 Annexure 1

Fire Safety General Guidelines

48
49
50
51
52
53
 Annexure 2

Emergency Fire Action Plan

Listed below are the procedures and other matters which are necessary to ensure fire safety
and evacuation in case of fire alarm within the company.

1. PROCEDURES IN EVENT OF FIRE/PROCEDURES ON DISCOVERING A FIRE

Fire Action Notices giving this information are displayed in prominent positions in all
buildings. Building occupants should ensure they are aware of this information.

2. CALLING THE FIRE SERVICE

Company fire alarm and detection systems are linked to a monitor.

Although this means fire alarm activations to these monitors should ensure an
emergency call to the fire service, it is recommended that where possible, from a
place of safety, without putting the caller at risk, a back up call should be made to

a. Gautam Budh Police Station

b. Gautam Budh Fire Department

This call is to confirm the fire alarm and building address only, it is not required to
investigate the source or reason for the fire alarm.

3. DURING A FIRE ALARM

When a fire alarm sounds all building occupants must evacuate to the assembly
point.
To assist in this evacuation each building has an Area Fire Officer and, where
appropriate, trained Fire Wardens.Security attends every fire alarm incident. They
meet the fire service at the main gate, direct them to the incident and along with
relevant building occupants and other staff as required, provide information and
assistance as appropriate.

4. BUILDING OCCUPANTS REQUIRING ASSISTANCE DURING FIRE ALARM

EVACUATIONS

Members of the public, visitors, guests attending functions may need additional
assistance during incidents such as these, as they may not have knowledge of
escape routes and fire procedures. To deal with this eventuality management units
must have prearranged and practiced procedures. These can be added by the
management units to this plan as an additional appendix.

Staff and visitors who are disabled may also need assistance. Comprehensive
guidance is available on the web site to assist staff to produce suitable plans
including personal evacuation plans (PEEPs) if appropriate.

5. USE OF LIFTS

54
 As a general rule lifts should not be used during a fire alarm, however some buildings
have lifts which may be used as part of the evacuation procedure for disabled
persons.
Lifts such as these can only be used as part of an agreed procedure with suitable
operators being trained in their emergency use.

6. TRAINING

Fire safety training is provided by SEPS between April and September. AFOs receive
notification each year offering arrangements to be made by the building occupant to
SEPS for suitable dates. General fire safety training including fire extinguisher
information is provided. Area Fire Officer and Warden training courses are also
available.
Fire Drills are carried out by SEPS staff between October and March each year.
AFOs receive notification each year offering arrangements to be made for suitable
dates. Two drills are carried out each year one per semester.
In certain circumstances training and drills can be carried out with the periods
described above. SEPS can be contacted for special requests.

7. TESTING AND MAINTENANCE OF FIRE EQUIPMENT

Area Fire Officers carry out certain routine tests and checks on fire alarms and
means of escape.
Other fire equipment is maintained by central maintenance contracts managed by
Estates and Buildings.

8. EMERGENCY PROCEDURES DURING TEMPORARY FAILURE OF FIRE

EQUIPMENT

During situations as above involving fire alarms, emergency lighting etc., Security
should be informed in the first instance. They can then notify Estates and Buildings,
Fire Officers or other staff as appropriate who will instigate suitable measures.

9. RECORDING TESTS, MAINTENANCE AND TRAINING

All of the above should be recorded in the relevant segments of the Fire Precautions
Register (Red Book) provided to all AFOs.

10. BUILDINGS UNFIT FOR USE FOLLOWING A FIRE

Should a building be unable to be returned to following a fire or similar incident,

authorized person will implement recognized procedures. Building occupancy will be
noted and suitable arrangements undertaken.

55
 Annexure 3

Duties of Area Fire Officer & Deputy Area Fire Officer

The Area Fire Officer (and Deputy) is the “Responsible Person” . His/her function is to
advise the Head of Department and Departmental Safety Personnel on matters relating to
fire precautions and emergency procedures.

His/her duties are:-

• To liaise with District Fire Officer and other District safety personnel regarding fire
protection requirements, and in particular the Departmental Fire Precautions
Register.
• To carry out certain daily and weekly inspections in his/her area of responsibility
regarding escape routes, fire alarm indicator panels and alarm tests.
• To ensure that new members of staff are given instruction on Fire Emergency
Procedures, that existing staff receive refresher training once annually, and that each
area for which he/she is responsible maintains a team of Fire Wardens, as
appropriate.
• To ensure that Fire Drills are carried out at least twice per annum.
• To ensure that all fire incidents, no matter how minor, are reported to the Safety
Officer.
• In collaboration with other Departmental Safety Personnel, ensure that in a situation
requiring the attendance of the emergency services (e.g. Fire Service), adequate
information is available to prevent, so far as is reasonably practicable, their being
exposed to risks to their health and safety.
• To ensure that in conjunction with Safety Officer, appropriate arrangements are in
place for assisting the evacuation of sensory or mobility impaired occupants, such
arrangements are to be agreed.
• To check the posting of appropriate warning fire signs and notices and to report
deficiencies to the Safety Officer & management.

56
Annexure 4

57