CO2 Flooding System – Fixed Fire Fighting

on Ships
CO2 flooding system or central bank CO2 system is one of the common fixed fire fighting system
installed on most of the ships. It releases carbon dioxide (CO2) in bulk quantity to a protected space
(such as engine room, cargo hold, purifier room, pump room, etc.) under fire. Smothering action of
CO2 extinguishes the fire thereby preventing spreading of fire to other parts of the ship. It consist of
several CO2 cylinders located in a separate room, called CO2 room. These bottles contain CO2 in
liquid state. When the fire in a protected space goes out of control or in a situation when the fire is
not able to extinguish by local fire fighting media, CO2 flooding system comes into picture. CO2 from
the bottles directed via common manifold, main valve and distribution pipe lines to nozzles through
which it is released to the protected space for fire extinction. Due to safety reasons, the CO2 flooding
system is manually released from a release cabinet located outside the protected space.

Why CO2 is used?

Carbon dioxide is the fire extinguising medium used in CO2 flooding system. It is an effective fire
suppression agent applicable to a wide range of fire hazards. It has a high rate of expansion which
allows it to work fast. When applied to a fire, CO2 provides a heavy blanket of gas that reduces the
oxygen level to a point where combustion cannot occur. Since carbon dioxide is a gas, there is no
clean up associated with a system discharge. CO2, a compound of carbon and oxygen, is a colorless
gas which cause coughing to occur when inhaled. At higher concentrations it is acutely toxic. Low
and high pressure CO2 is used for the fire protection of machinery spaces, pump rooms, cargo holds,
paint stores and galley exhaust ventilation ducts on board ships.

There are several advantages for the CO2 as a fire fighting medium. They are:

▪ Density is 1.5 times higher than air. So CO2 settles down and displaces air.
▪ It can be easily liquefied and bottled.
▪ 20% – 30% CO2 concentration extinguishes fire by smothering
▪ Non-corrosive
▪ Non- conductor of electricity
▪ No residues left after application
▪ No deterioration with age
Similarly there are some disadvantages also, such as:

▪ CO2 is highly asphyxiating. 9% concentration causes unconsciousness within minutes

▪ Very little cooling effect. So there is danger of re-ignition.
▪ When discharged, solid CO2 particles present and generate sufficient static electricity to
produce spark.
Explanation of CO2 Flooding System

As mentioned earlier CO2 flooding system floods the protected space under fire with carbon dioxide,
which displaces air, thereby removing one leg of fire triangle for the extinction of fire. CO2 flooding
system consist of main CO2 bottles, common manifold, master valve or distribution valve and
distribution pipe lines with nozzles as shown in the figure below.

CO2 from the main bottle is released by a ‘CO2 release cabinet’ as shown in the figure. As soon as the
release cabinet door is opened, a micro switch is activated. The micro switch will ensure the
activation of CO2 warning alarms and ventilation shut off. CO2 release cabinet or release box consist
of two pilot CO2 cylinders or bottles containing CO2 gas inside. The pressure of CO2 inside these
pilot bottles is same as that of main CO2 bottles. Only quantity of gas is different. For releasing CO2
to the protected space, one of the pilot bottle valve is opened. Now CO2 reaches two valves marked 1
and 2. First valve 1 is to be opened. Then CO2 passes through a non return valve and opens
pneumatically operated master valve. Now master valve is opened. Next, open valve 2 in the release
cabinet, which supply CO2 to main CO2 bottle head assembly through a non return valve and ‘time
delay unit’. Function of the time delay unit is explained below. Head assembly consist of a pressure
operated cylinder valve. This pressure operated cylinder valve prevents CO2 from bottle coming to
the common manifold. As CO2 reaches the head assembly from pilot bottle, pneumatic actuator in
the head moves and opens the pressure operated cylinder valve. Then CO2 from main bottle escapes
to the common manifold via non return valve as shown. Each of the main CO2 cylinder have a head
assembly and non return valve. The pilot CO2 line is connected to all these heads. All the CO2 from
the main bottles now release to common manifold. Since the master valve is already open before,
CO2 from manifold is released to the protected space through distribution pipe lines and nozzles.

As you can see in the diagram, there are two CO2 release cabinets. One is local release cabinet and is
located in the CO2 room itself. One more remote release cabinet is used, which is located in a remote
place such as fire control station. This facilitates operation of CO2 flooding system from a remote
place other than CO2 room. Both release cabinets are connected in parallel and non return valves
fitted in the lines prevent back flow of CO2. Also two pilot CO2 bottles are placed in the release
cabinet. Only one is sufficient for the operation of both master valve and CO2 bottle head assembly.

CO2 flooding system explained here protects only a single space. There are systems which can
protect multiple spaces such as engine room and pump room together. In that case separate release
cabinets will be there for engine room and pump room. Main CO2 bottles are shared for engine room
and pump room according to the volume of the spaces.

Time Delay Unit in CO2 Flooding System

CO2 from the pilot bottles in release cabinet reaches main CO2 bottle head assembly through a time
delay unit. Function of this time delay unit is to delay the supply of CO2 to the head assembly for 60 –
90 seconds. In other words, when valve 2 in the release cabinet is opened, CO2 reaches only after 60
to 90 seconds to the head assembly. Reasons for providing such a s delay in CO2 flooding system are
given below.

1. As soon as CO2 release cabinet opens, alarm is sounded in the protected space. A time
delay of 60 to 90 seconds give sufficient time for any personnel in the protected space to
escape, even after the operation of both valves in the release cabinet.
2. If CO2 is released from main bottles to the common manifold before opening master valve,
there may be difficulty in opening master valve because of the bulk CO2 pressure acting
on it. Because of the time delay, positive opening of the master valve is ensured before
releasing CO2.
3. Regulation per International Code for Fire Safety System (FSS Code) 2.1.3.2 says, “The
pre-discharge alarm can be automatically activated (e. g. by opening the release cabinet
door). The alarm shall operate for the length of time needed to evacuate the space, but in
no case less than 20 seconds before the medium is released.”

What are the requirements of CO2 Room

In CO2 flooding system, carbon dioxide bottles are placed in a separate room called CO2 room. The
requirements for location, accessibility, use and ventilation of CO2 storage spaces as per IMO are:

▪ Spaces for storage of cylinders or tanks for extinguishing gas should not be used for other
purposes.
▪ These spaces should not be located in front of the forward collision bulkhead.
▪ Access to these spaces should be possible from the open deck.
▪ Spaces situated below the deck should be directly accessible by a stairway or ladder from
the open deck.
▪ The space should be located no more than one deck below the open deck.
▪ Spaces where entrance from the open deck is not provided or which are located below
deck are to be fitted with mechanical ventilation.
▪ The exhaust duct (suction) should be lead to the bottom of the space.
▪ Such spaces should be ventilated with at least 6 air changes per hour.
Requirements of CO2 Flooding System

1. Discharge requirement is, at least 50% of CO2 discharge to be carried out in 1 minute
and at least 85% discharge in 2 minutes.
2. CO2 usage on ships has to abide by few safety regulations, as on ship there are
lives at stake and measure to fight accidents are few .The main regulations are:
 • If the CO2 system is installed in the cargo spaces, the quantity of CO2 available
should be sufficient enough to give at least a minimum of 30% of the total volume of
the largest space that is protected by the CO2 system.
• If the CO2 system is installed in machinery spaces, the quantity of CO2 available
should be sufficient to give at least a volume equal to either of the following :
.

a) 40% of the total volume of the largest machinery spaces that is protected by
the CO2 system. (The volume should exclude that part of the casing where the horizontal
area of the casing is 40% or less then the horizontal area of the space taken into
consideration and measured midway, between tank top and lowest part of casing)

b)35% of the total volume of the largest machinery spaces that are protected by the CO2
system including the area covered by the casing.

3. Safety procedures must be there against unauthorized use of the system.

4. Machinery space to be fitted with audio-visual alarm and ventilation blower trip.
5. Alarm must trigger well before operation of CO2 flooding system.
6. Permanent piping arrangements should be made.
7. Manifold, distribution piping to be pressure tested.
8. Diameter of associated pipe lines in the system should not be less than 20 mm.
9. Copper and flexible pipes are allowed between CO2 cylinder and common manifold.
10. Distribution pipes to cargo spaces should not pass through engine room.
11. All stop valves to be checked every month to ensure their working and position.
12. The CO2 flooding system installation to be checked monthly for any leakages.
13. All control valves to be tested annually.

The time delay can be achieved in different ways. Out of these, two types of time delay unit is
commonly used in CO2 flooding system on board ships. One is electrical type, which has an AC 220 V
power supply, a pressure switch, timer and a solenoid valve as shown in the figure below.
 Power source is
always available for the unit. Solenoid valve is normally in closed position. When CO2 from pilot
cylinder (CO2 release cabinet) reaches the time delay unit, the pressure acts on the pressure switch.
This closes the pressure switch. But the timer allows power supply to the solenoid only after 60-90
seconds, the timing can be adjusted as required. As soon as the specified time is reached, solenoid
becomes energize and the solenoid valve will open. This allow passage of CO2 to the pressure
operated cylinder valve of main bottle. Normally a by pass valve is also fitted across this time delay
unit which can be used in case the unit goes defective.

Another type of time delay unit uses an empty bottle fitted just before the head assembly. This
empty bottle fills first before supplying pressurised CO2 to the head assembly. This is more reliable
since there is no electrical components involved. Figure below 000000shows two time delay units,
one for engine room and the other for purifier room.
CO2 Main Bottle Head Assembly

Head assembly mainly consist of a cylinder valve, which is operated by a pneumatic actuator and
linkages as shown in the figure below. CO2 from the release cabinet reaches the pneumatic actuator
through time delay unit and actuator operates the cylinder valve to release CO2 from main bottles to
the common manifold.
The pressure operated cylinder valve shown in the figure above can also be manually
operated by use of a lever inserted into the top of the valve. Free space above the
valve should be minimum 200 mm. The closing nut is to be screwed tight to the valve
outlet during transport and storing of cylinders with valve fitted. The cylinder valve is
always supplied with a cotter pin or split pin as shown for securing cylinder after filling
and during any maintenance on the CO2 flooding system.
Bursting Disc in CO2 Flooding System

The pressure of CO2 inside the bottle depends on the temperature of the surroundings. As
temperature increases, pressure also increases. Therefore to safeguard against abnormally high
pressures inside the bottle, a bursting disc is provided on the head assembly as shown in the figure
above. When the CO2 pressure inside the bottle increases to about 200 bar, bursting disc burst and
releases CO2 to the CO2 room. Pressure inside the bottle build up to such a high value means there is
a fire inside CO2 room. Here, CO2 released from the bottle itself extinguishes fire inside the room.
For better understanding have a look at the pressure- temperature relationship at different filling
densities from the graph below.
 From this
graph, pressure of CO2 at different temperatures can be identified.
Function of Pressure Switch, Pressure Gauge in Manifold

Pressure switch is fitted in the common manifold to identify any leakage of CO2 gas from bottles to
the manifold. The pressure switch activates warning alarm for the leakage. Similarly pressure switch
will activate alarms while actual operation of CO2 flooding system. A pressure gauge is also fitted on
the manifold to read any gas pressure inside. A valve for pressure testing of the system is also
connected to the pressure gauge connection as shown in CO2 line diagram.
Why Relief Valve is Required?

There is a relief valve fitted in the manifold of CO2 flooding system. Function of the relief valve is to
release the CO2 pressure in the manifold to the atmosphere outside CO2 room. Such a situation
arises when CO2 get released from the bottle and master valve is still closed. Set pressure of relief
valve is about 180 bar. Again, set pressure varies with the system design and regulations. A relief
valve is required for two purposes:

1. If the pressure of fluid in a pipe line increases beyond the designed working pressure,
there must be a pressure relief mechanism for bringing down the pressure to safe guard
the system. In the case of CO2 flooding system, CO2 will accumulate in the manifold when
it is released from the bottle and master valve is closed. Pressure of CO2 is 55 bar at 20
degree Celsius. As CO2 takes temperature from surroundings, its pressure also increases
to dangerous levels. Since these pipes are pressure tested to 190 bar only, a relief valve is
necessary in the manifold.
2. Any pressure accumulate in the manifold may release other CO2 bottles which are intact,
if the non return valve between bottle and manifold is damaged.

Procedure of Releasing CO2 to the Engine Room on Ships

1. Muster and take head count.

2. Master will take decision, depending upon the situation and as per the company policy.
3. If total CO2 flooding of engine room is to be done, master will consult with chief engineer.
4. Nearest coast guard to be informed as soon as possible.
5. Ensure proper sealing of the engine room.
6. Make sure emergency generator is running and on load. Power is required for running
emergency fire pump for boundary cooling.
7. All access doors, vent flaps, blower flaps, skylights, hatches, fire flaps, to be closed.
8. Quick closing valves to be closed.
9. Emergency stops for lube oil pumps, fuel oil pumps to be operated.
10. All machinery in engine room to be stopped.
11. Ensure all personnel vacated engine room.
12. CO2 must be released by competent engineer.
13. Break the glass and take out key for CO2 release cabinet from key box. Using local CO2
release cabinet is preferred.
 14. Open the release cabinet. Audio visual alarms will sound and ventilation blower trips will
activate.
15. In the CO2 release cabinet, open pilot cylinder valve first. Now open valve 1 for master
valve first. Then open valve 2 for CO2 releasing mechanism. Co2 will be released after 60-
90 seconds of time delay.
16. Now the system pressure can be checked from the pressure gauge on the manifold.
17. If CO2 is not released, then follow emergency releasing procedure. Open master valve
manually and open each CO2 main bottle by manual actuation lever.
Important Notes on CO2 Flooding System

▪ CO2 flooding is the final course of action, used only when all else has failed. Proper
sealing of the engine room is essential for effective extinction of fire. There were incidents
like CO2 is released, effective smothering did not occur due to improper sealing of engine
room and fire remained unextinguished.
▪ To obtain a total flooding of engine room, about 35% by volume of CO2 is required in 2
minutes. This will reduce the oxygen content of the air in engine room to less than 15% to
extinguish the fire. At this CO2 concentration human life cannot be supported.
▪ Typically it takes about 15-20 seconds after release of CO2 before the concentration in
engine room reaches a dangerous level.
Safety Precautions After CO2 Release

After CO2 flooding system is operated efficiently, engine room fire will extinguish by smothering
action. But before engine room entry is made or space ventilated, it is recommended to obtain expert
advice from shore. Nearest coast guard can be contacted for getting assistance for the same.

1. The first question is, how to make sure that CO2 is actually released after the operation of
CO2 flooding system. When Co2 is released there will be a loud noise of gas escaping to
the protected space. CO2 bottles can be felt cold after releasing. Visual inspection of the
operation of, pressure operated cylinder valves also can be carried out.
2. CO2 has very little cooling effect. So there is a danger of re-ignition of fire when engine
room is ventilated immediately. Keep the boundary cooling running to reduce the
temperature of the engine room.
3. Ventilation of engine room should not be started until it has been definitely established that
the fire has been extinguished completely, which will take several hours.
4. Engine room to be sufficiently ventilated before entering.
5. Entry to be carried out by trained personnel wearing breathing apparatus.
6. Even after fire has been extinguished completely, never bring bare flame such as candle
light or lighted cigarette into the burnt room, other wise fire may break out again due to
explosion of combustible gases, if any.
7. In order to allow persons to get away quickly and safely in case of fire, entrances and exits
shall be always kept clear.
8. Back up team or support team to be ready in case any difficulties happens in side.
9. An attendant should be instructed to remain at the entrance of the engine room.
10. An agreed and tested system of communication to be established between attendant and
team inside engine room.
11. In case any emergency occur to the team inside engine room, the attendant is not
supposed to enter inside before the help has arrived.
12. In the event of ventilation system fails, the personnel in the space should leave
immediately.
What are the safety devices on CO2 flooding system ?

▪ Master valve with alarm switch.

▪ Relief valves at manifold.
▪ Stop valve and pull handle are in lock release cabinet and alarm switch.
▪ Safety bursting disc at each CO2 bottle.
▪ Leakage detecting pressure switch on manifold.
▪ Non return discharge valves after CO2 bottles.