FF Description - Docxnew, New

FIRE PROTECTION SYSTEM
1 PROCESS DESCRIPTION
2.1 Introduction
Fire Protection System (FPS) shall be provided as per the applicable Ethiopian Government
norms. The FPS for sugar plants falls under the category of Ordinary Hazards. The drawing
given with this document helps as reference for detail design.
1.2 OBJECTIVE
The fire system categories of the fire fighting and suppression systems are:
 Prevent fire damage to assets
 Preventive & manage the fire and limits escalation to the extent practical
 Minimize the effect of a fire in plant facility
 To extinguish the fire in the beginning where it is considered safe to do so
The application of fire cases:
 Limit the material damage by reducing the probability of escalating the fire
within the fire area. The objective shall be to limit the fire within its location
i.e. where it has started and prevent its escalation to the neighbouring areas;
 Reduce the heat radiation to enable safe escape and evacuation to the main
entrance;
 Reduce the total heat flux to enable an effective fire fighting.
Major incidents often escalate from relatively minor occurrences involving the three elements
of the fire triangle, namely:
 Fuel;
 A source of ignition; and
 A source of oxygen (from air).
Exclude any of these elements and a fire will be avoided or extinguished, however if they are
all present, a fire will continue and may well escalate by involving further sources of fuel.
Thus, the basic requirements of the fire and gas detection and protection system are as
follows:
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 Detect the release of fuel/gas as rapidly as possible: Install fire detector at

proper location
 Upon detection of fire:
o Isolate sources of ignition:
o use the applicable fire fighting devices
o Apply extinguish ant (fire only): depend on the fire scale, use the
applicable fire fighting device, fire fighting medium.
o Protect adjacent equipment to prevent escalation of the incident:

Cooling the adjacent equipment by water hydrant, monitor, etc
o Exclude air where possible: especially where the fire source inside
the closed space, then an attempt to isolate air ingress could
significantly reduce the fire escalation prior to complete
extinguishing
o If the fuel source ignites, detect the fire as quickly as possible: proper
location of flame detector could help operator identify the location,
seeing the possible danger, use proper extinguishing media, minimise
the extent of fire.
1.3, CODES AND STANDARDS

The fire protection facilities shall be designed in accordance with NFPA and local regulations
and laws concerned, with international regulations.
Equipment, materials and devices used for the fire protection facilities will be designed,
manufactured, tested and inspected in accordance with the requirements of the authority
having jurisdiction on manufacturer‟s countries.
1.4, BASIS OF DESIGN

Fire Fighting Design is based on the “Single Fire Risk” concept, which means that only one
major fire will occur at a time and fire will not take place simultaneously at different
locations. There are several fire case (fire zone), where each fire zone will be measured the
fire water demand, thus the largest fire water demand is selected as the design basis.
1.5, SYSTEM DESCRIPTION

Fire fighting systems by medium type in the plant consist of:
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1. Fire water hydrant, hose box, Fixed monitor
2. High Velocity Water Spray System
3. Raw Water Storage and Pump Station
4. Portable Extinguisher (Dry chemical, CO2, Water/Gas, Sand Bucket)
5. Automatic Extinguishers
6. Fire Detection and Alarm Systems
1.6, FIRE FIGHTING AREA

Following Areas might require special fire fighting equipment:
Processing Plant, Storage Tank:
This includes Outdoor hydrants, fixed monitors, manual Extinguishers and Fuel Storage
Facilities.
Office and Administration Buildings:
This includes indoor hydrant/Standing Pipes/ and manual fire fighting items.
Control room, UPS room, Telecommunication room, Electrical room:
As water is not allowed in these areas, manual CO2 Extinguisher and Automatic Extinguisher
shall be used to suppress fire in these locations.
Transformer Area:
As this room/area is normally remains unmanned, Fire Detection and High Velocity Water
Spray system shall be selected.
Steam Turbine Building and Boiler House:
This includes hose reels, outdoor hydrant, Fixed Monitors and portable extinguishers as well.
Storage Areas:
Manual Extinguishers, Hydrants and Fixed Monitors will be selected.
1.7, SYSTEM COMPONENT

The fire hydrant system shall consist of water storage tank, pumps, valves, pipe lines with
branches and nozzles, control panel, etc. The hydrant pipes shall be laid 1.1 m below the
ground level. The pipes could be anticorrosive type or could be wrapped with anticorrosive
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tape. The system shall be designed such that the extreme point shall have sufficient pressure.
The capacity of the system shall be designed for six hours. Proper sluice valves at each
branch shall be provided for isolating the system. All hydrant accessories such as hose box
for housing two hoses, hydrant valves, etc. shall be provided. High velocity water spray
system for Transformers shall be provided. The system shall comprise of pipeline and spray
nozzles. The system shall have annunciation panel, test and drain connections. The system
shall be as per Tariff Advisory Committee (TAC), National Fire Protection Association
(NFPA) or equivalent or better International Norms. The Contractor shall obtain the
certification of the system after commissioning from respective Government authorities.
Automatic fire detection and alarm system shall be provided. The location of the detectors
shall be indicated in the drawing. The system shall consist of detectors, alarm system,
cabling, panel, etc. Manual fire alarm system shall also be provided. Sufficient points shall be
provided in the plant so that in the event of fire, it is possible for operating personnel to press
the fire alarm system and alert the people. Portable type fire extinguishers shall be provided
at suitable locations. The fire extinguishers as per the type of fire shall be placed at suitable
locations. Sand buckets duly filled with sand shall be provided at suitable locations for handy
operations.
EQUIPMENT CODE QUANTITY DESCRIPTION
300 Fire Protection system
301 1 Water storage tank
302 2 electrically driven pumps
303 1 Diesel engine (DE) driven pump
304 1 Jockey Pump
305 1 Pump room
306 Lot Hydrant System
307 Lot Hydrants and fixed monitors
308 Lot Hose pipes and nozzles
309 Lot Fire Extinguishers
310 Lot High Velocity Water Spray System
311 Lot Electrical
312 Lot Automatic fire extinguishers
313 1 Fire alarm
314 2 Mobile firefighting units
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1.8. TECHNICAL DISCRIPTION OF EQUIPMENT IN FPS

Brief Technical specification of equipment in Fire Protection System is given below.
18.1, WATER STORAGE TANK (301)
Water for the hydrant service will be stored in a separate underground Rcc storage tank.
Fire water supply fire water will be stored in a basin with reserved dedicated capacity
equal to six (6) hours of maximum fire water demand. To maintain the six hour fire water
demand the water level should be maintained constant at minimum level of 1m that the
total water volume in the tank will be 1200 m3 /40m x 30m x 1m size/.
1.8.2, ELECTRICALLY DRIVEN PUMP (302)

The Fire Pumping System Consists of:
a. Fire Water Main Pumps; comply with NFPA-20, two motor drivers as duty
pumps and one diesel engine driver (standby). The diesel engine fuel supply is
taken from dedicated fuel tank with capacity enough for 8 hours engine
operation.
b. Fire water jockey pump, comply to NFPA-20, one motor driver as duty pump
with no spare, with function to maintain the fire water main header pressure at
required pressure
Two electrically operated vertical, submersible pumps shall be installed. These pumps shall
be exclusively for firefighting usage and no other connections shall be tapped except those
for Water Hydrant Service Rings (WHSR). Capacity of the pumps shall be 273 m3/h with
delivery pressure of 8.8 kg/cm2(g) as per TAC. The pumps shall be coupled to electric
motors. The drive motors shall be Totally Enclosed, Fan Cooled (TEFC) wound to Class E
insulation. The windings shall be vacuum impregnated with heat and moisture resisting
varnish and suitable to be operated at 50 ºC ambient temperature. Suitable foot valve shall be
provided for vertical submersible pumps. Power supply to the pump shall be from the main
power control center in Power House. The power supply cable shall be laid underground and
shall not pass under any building or permanent structure. The electrical installation shall
confirm to relevant standards and codes applicable for fire protection system.
Initiation of Fire Fighting Systems may be manual, automatic or both.
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The fire water pump system should be selected to deliver the pressure and flow required for
the operation of water based systems (hydrants, monitors, HVWS etc.) sufficient to meet
typically the single largest credible fire in a fire area plus any anticipated manual fire fighting
demand.
The fire pumps shall be able to deliver fire water minimum 7 brag at the longest and/or tallest
point, with the largest fire water requirement in the biggest area. The pump system shall
include one jockey pump, two electric motor driven fire pumps, and one diesel engine driven
pump.
According to NFPA -20, fire water pumps shall be able to deliver not less 150% of rated
capacity.
Fire Water Pumps, Drivers and Controllers shall be installed in the Fire Pump House, which
is located in the safe area (non-hazardous area).
Fire water ring main shall normally be pressurized using Jockey Pumps. As per NFPA 20,
jockey pumps shall have discharge pressure sufficient to maintain the desired fire protection
system pressure.
For this project, design of fire water for the facility shall be able to provide adequate flow and
pressure to meet the fire water demand requirement for duration 6 hours.
The fire water pump system shall be operated as follows:
The main fire water pump shall be provided with automatic starting facilities which will be
activated for any of the following causes:
 When the fire water ring main pressure is Low-Low

 Local Manual Start (MCC Panel)
The fire water ring main pressure is always maintained by the jockey pump that starts
automatically when the fire water header pressure is low (Lower Pressure) and stop when the
fire water header pressure is high (Higher Pressure).
For any reason, if the fire water rings main pressure falls down to 6.5 brag the duty fire
water pump will start automatically. When the duty fire water pump failed to start or nor able
to develop the required pressure and the ring main pressure continues to drop to 6 brag, the
stand by pump will start automatically. (Intermittent Procedures)
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Pumps can also be started manually from the pump local control panel. The only way for the
operator to shut down the fire pumps is by pressing the local stop push button.
1.8.3, DIESEL ENGINE (DE) DRIVEN PUMP (303)
Diesel engine driven vertical, submersible pump of similar capacity to electrically driven unit
shall be provided as standby pump. The pump shall be exclusively for firefighting usage and
no other connections shall be tapped except those for water hydrant service ring.
1.8.4, JOCKEY PUMP (304)

One jockey pump shall be provided to take care of the system losses. The capacity of the
jockey shall be 10.8 m3/h with delivery pressure of 8.8 kg/cm2(g).
1.8.5, PUMP ROOM (305)

2 # of electrically driven vertical submersible pumps, 1 # of DE driven vertical submersible
pump and 1 # jockey pump motor driven shall be installed in the pump house. Suitable
capacity priming tank shall be provided for the jockey pump at elevated location. The MCC
with necessary instruments, gauges etc. shall be in the pump house. Vapor proof incandescent
lighting shall be used for the pump house.
1.8.6, HYDRANT SYSTEM (306)

The distribution system shall be designed to ensure a minimum residual pressure of 7 brag is
achieved at the longest and/or tallest point while flowing at the maximum fire water demand.
Hydraulic calculation shall be carried out to assure proper operation of the fire fighting
system. The hydraulic calculation of fire water ring main shall be based on Hazen-Williams
formula with C = 120 of friction losses..
The fire water distribution design shall ensure that at the largest fire water flow requirement
the velocity in any one section of the ring main does not exceed 2 m/sec.
The fire water ring main shall be generally laid underground and parallel to plant roads or in
open space. The size of fire ring main shall be uniformly 250mm.
Sluice Valves with post indicator shall be provided such that no more than 300 meters of line
containing hydrants, monitors, deluge systems or hose reels are lost due to any line failure.
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Underground piping and fittings used for the fire water ring main and lateral equipment shall
be U-PVC. /carbon steel, which is internally non-lined and externally coated or other non-
corrosive pipe types can be used/. No fire water piping shall be installed beneath buildings or
stationary equipment.
The ring main shall have hydrants located round process units and any loading areas at
approximately 60 metres intervals. In other storage areas, off-sites, office, workshops and
other administration areas the spacing shall be at approximately 30 metres and in small areas
the hydrant distance will be limited to 15m.
Any area of the plant shall be accessible from two opposite sides by 2-1/2 inch hose with
maximum length of 30 m.
The hydrant mains shall be laid underground and shall be of the following construction:
a. Mild steel pipes, of Medium grade conforming to IS : 1239 or IS : 3589 or equivalent
British standard. The pipeline shall be of welded construction to withstand minimum
10.5 kg/cm2(g) pressure without fall in pressure or bursting of pipes or weld joints.
The entire piping shall be coated with suitable non-corrosive paint and wrapped as per
IS:10221.
b. U-PVC or Filament Pipe with smooth internal finishing quality and with pressure
resistance capacity of 16 bar/such 80/.
Underground mains shall be laid 1100 mm below ground level. The mains and hydrant points
shall be laid and erected at least 2 m away from the main factory building. Suitable supports
of either concrete or fabricated saddles at regular intervals shall have to be provided below
the hydrant mains. At suitable points, cut off valves shall be provided in the piping mains to
segregate and isolate sections of the ring mains as per requirement. These valves shall be
encased in suitable valve chambers/pit/. Pipe fittings going underground, shall be of Cast Iron
of proper grade conforming to IS : 1538 or BS 5041 or PVC or Filament whereas those fitted
above ground shall be of Medium grade wrought or mild steel conforming to IS : 1239 Part II
equivalent BS or malleable iron fittings conforming to IS : 1879 Part I to X or equivalent BS.
1.8.7, HYDRANTS AND FIXED MONITORS (307)

All fire hydrant outlets shall be compatible with the design code applicable and shall be of the
dual pressure type. The change over from low to high pressure or vice versa shall be by a
simple local operation.
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The water hydrant design shall be a 80mm or 110mm risers with screw connection, wet barrel
type and equipped with two (2) 2 1/2" (63 mm) valves NH thread couplings. All outlets are to
be fitted with a cap and retaining chain.
All hydrant outlets shall be erected 1 m above ground level. The stand post shall be of 80mm
in diameter for single headed hydrants. The hydrant shall be of Mild Steel stand post with
bends and flanges, screw down type with outlet angled towards ground as per IS: 5290.The
stand post shall be painted fire red (shade no 536 as per IS: 5). The hydrant couplings shall be
of gun metal of the instantaneous spring lock type of 63mm diameter and valves shall be of
screw down type. Each hydrant valve shall be provided with blank cap and chain. Pipe work
shall be carried out as per the drawings approved. During erection general norms in respect of
minimum working clearance and operating space shall be observed. Platforms, access,
walkways etc. which are necessary for operation and maintenance of valves, along with
required instruments shall be provided. Pipe supports, anchors, guides etc. shall be provided
as per ANSI B 31.3, B 31.2, B 31.3, B 31.4, B 31.5 as relevant. Pipe joints shall be butt-
welded types. Flanges shall be provided on straight lengths at suitable parts such as bends,
tees as required for easy erection and maintenance. Flanged joints shall also be provided to
match the connecting ends of equipment, valves, fittings, etc.
In case of using Cast Iron Piping, Only qualified welders shall carry out the entire welding.
The welding joints shall be by electric arc and gas welding procedure as per IS: 823 and IS:
1323 respectively. Valves shall be located in valve chamber of masonry construction with
RCC removable covers. The valve chamber/Pit/ size shall have enough space to carry out
repairs and maintenance work. Where soil conditions are unsatisfactory masonry or equal
supports shall be provided at regular intervals.
Fixed monitors should be capable of swiveling 360 º and should be suitable to pour fire
quenching water at highest point in building / equipment which is to be protected against fire
hazard by the respective fixed monitors.
Fixed water monitors may be used to provide water coverage and supply water-foam
solution. Fire monitors shall be of the hand lever operation type with locking devices on a 4"
riser, and shall allow full rotation movement of 360º and elevation movement from 45º below
horizontal to 85º above horizontal. The monitor nozzle shall be of the variable type with a
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water discharge pattern ranging from straight stream to fog. Water monitors shall have a
straight stream range of 30-60 m in still air conditions at the normal water operating pressure
with a flow rate min.2000 lit/min at minimum 7 brag.
1.8.8, HOSE PIPES AND NOZZLES (308)

The hoses shall be stored in glass front panel wooden boxes painted red and shall be near the
fire hydrants. Each hose box shall contain two hoses of length 15 m each. All hoses shall be
either unlined canvas as per IS : 4927/IS : 636/IS : 8423 or equivalent BS. Alternatively the
hoses can be Rubber lined woven jacketed complying with type II reinforced rubber lined as
per IS: 636 or equivalent BS and permitted to be used up to a maximum of 50 % of total hose
requirement of the hydrant system.
All couplings shall be of instantaneous spring lock type of 63 mm dia size; and the nozzles
shall be 32 mm. Couplings, branch pipes, and nozzles shall be as per IS : 903 or equivalent.
Couplings shall be attached to the nozzles as stipulated in the Manual. The total number of
nozzles shall be half the total quantity of hoses.
Hose boxes (cabinets) shall be located adjacent to each hydrant on site. They shall be
manufactured of steel and be of the self-standing type, colored red, glass fronted box.
The contents of each cabinet shall be:
• 2 off 30 meter lengths of 63 mm hose with 63 mm NH couplings
• 2 off 15 meter lengths of 63 mm hose with 63 mm NH couplings
• 1 off adjustable jet/fog nozzles with inlet NH couplings
• 2 off 63 mm EA adaptors
1.8.9, FIRE EXTINGUISHERS (309)

The capacity and type of extinguisher shall be as per the class of fire. The location of the
extinguishers shall be marked and the drawing shall be approved from concerned authorities.
Fires & Fire Extinguishers are classified into 5 classes as specified below.
Class / Category Class of Fire Suitable type of Extinguishers and appliances

A /Fires in ordinary combustibles
(Wood, vegetable fibers, cloth paper and
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The like) Chemical Extinguishers of Soda Acid, Gas /

expelled water and anti-freeze types, and water
buckets
B/ Fires inflammable liquids,
Paints, grease, solvents and
the like
Chemical extinguishers of foam, Carbon
Dioxide and Dry Power types and sand buckets
C/ Fires in gaseous substances
Under pressure
Chemical extinguishers of Carbon Dioxide and
Dry Powder type
D/ Fires in Reactive Chemicals,
Active metals
Special type of Dry Power Extinguishers and
sand buckets
E/ Fires in electrical equipment Chemical Extinguishers of Carbon Dioxide and
dry powder type and sand buckets
According to above classification, the categorization of plant and equipment is as under:
Class A : Offices
Class B : General and sub stores, workshop, Mill and Powerhouse
Class C : Area of General stores where Oxygen and Acetylene gas cylinders are stored
Class D : Sulphur store
Class E : Parts of different factory sections in which electrical equipment are installed
viz. Mill house, Power house, Work shop, Boiler, Clarification house, Boiling
house, Sugar house and area where Transformer is installed.
Class of fire is indicated against respective sections wherever appropriate. The quantity of
appliances to be located at different location shall be suitably selected. Their location is to be
fixed in such a way that at least one set of appliances is placed at the entrance of respective
building/floor; and that a person is not required to travel more than 15 m to reach the
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appliances. All the buckets and water type extinguishers shall be 9 liter capacity, and all the
dry powder extinguishers shall be of 5 kg capacity (except those installed to protect
electrically driven equipment installed at a height on platforms/pedestals which should be of
2 kg capacity. All CO2 extinguishers shall be of 4.5 kg capacity; unless stated otherwise. For
protection of equipment installed on platforms/pedestals, extinguishers shall have to be
located near the platforms/pedestals to have quickest access from the ground floor.
Offices (Class A)
Offices are shown in administrative (ADM) block in the drawing No. 4LO-1927 R10 Fire
Hydrant Service Ring. In case of multi-story or multi-floor buildings, each floor shall have 3
nos. of water type extinguishers.
General stores (Class B, C)

The store designed to store spares, tools, consumables, hardware, paints, stationary,
lubricants, grease, etc. shall be provided with sand buckets and dry Powder extinguishers.
There shall be an open storage area adjoining the General store to store steel structures,
refractory bricks, lubricants, drums, industrial gasses etc. The open storage space shall have
sand buckets and dry Powder extinguishers.
Sulphur store (Class D)

Not applicable for Tenaha Sugar Factory Project.
Cane yard and mill house (Class B and E)
For covering the area of mill house, sand buckets, dry Powder extinguishers and CO2 fire
extinguishers are to be installed.
Power house (Class B and E)

Power house has Turbo generator sets, Diesel generator sets, protection switchgear, control
panels, MCC‟s units. Also for daily use some lubricant drums may have been kept on the
floor. To cover the area, sand buckets, dry powder extinguishers and CO2 extinguishers shall
be provided on the ground floor as well as on the T.G. set floor at 8 m level.
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Factory workshop
The workshop which houses various machine tools such as lathes, planning, shaping, drilling,
grinding machines, foundry, fabrication and fitting shops, etc shall have sand buckets, dry
powder extinguishers and CO2 extinguishers.
Boiler (Class B and E)

Boiler area consisting of boilers, its accessories, ancillaries and MCCs with furnace oil firing
equipment is on ground floor and the various components of boilers shall be on platforms at
various levels. Sand buckets, dry powder extinguishers and CO2 extinguishers shall be
provided for this station at various levels.
Clarification House (Class E)

Clarification house consisting of various electrically driven units shall be provided with sand
buckets, dry powder extinguishers and CO2 extinguishers.
Boiling House (Class E)

Boiling house consisting of various electrically driven units shall be provided with dry
powder extinguishers and CO2 extinguishers.
Sugar House (Class E)

Sugar house shall be provided with sand buckets, dry powder extinguishers and CO2
extinguishers.
For covering equipment installed on the platforms, dry powder extinguishers shall be
installed.
Water supply pump house and Effluent treatment plant (Class E)

This house consists of some electrically driven units. For covering the area sand buckets, dry
powder extinguisher, and CO2 extinguisher shall be installed.
Transformer (Class E)
Transformer shall be protected by sand buckets, dry powder extinguisher and CO2
extinguishers.
Sugar goes down
Sugar go down shall be provided with water type extinguishers.
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1.8.9.1, MANUAL FIRE EXTINGUISHERS AT SELECTED LOCATIONS
1.8.9.2, FIRE AT FUEL TANK

Manual Fire Extinguishers and External Fire Hydrants applied in this area. Fixed
water monitors of at not less than 2000 lt/hr shall be placed at strategic location to be
used for additional cooling provided by spray systems.
1.8.9.3, FIRE AT PROCESSING PLANT AND POWER GENERATION

For general process area fires, a review of major equipment items shall be performed
during the detail engineering. Water Hydrant System and various types of portable
Fire Extinguishers used.
1.8.9.4, FIRE AT BUILDING

Any other buildings such as Offices workshop, raw water treatment plant, waste water
treatment plant, will be equipped with various types of Portable Fire Extinguishers
1.8.9.5, FIRE AT STORAGE AREAS
Raw material stores, finished product store and process input stores will be equipped
with various types of manual extinguishers, External water hydrants and Fixed
monitor system.
Dry chemical hand held fire extinguishers shall be located strategically throughout the plant
to meet the following criteria:-
• In the process areas one (1) for every 400 m2 with an additional one at every
elevated floor level.
• In buildings one (1) for every floor or one (1) for every 300 m2.
“ABC” type or other type portable Dry powder fire extinguishers shall be provided in
building in general.
- Capacity : nominal 5 kg and 2kg
- Accessories : metal wall brackets for installation
Carbon dioxide portable fire extinguishers shall be provided for specific hazard areas, where
an electric fire would be anticipated, i.e. in control room and electrical substation.
- Capacity : nominal 4.5 kg
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- Accessories : metal wall brackets for indoor installation
Water Gas Extinguishers shall be used in offices and finished product areas
- Capacity : 9kg
- Accessories :metal with bracket
Sand Bucket fire Extinguishers shall be provided for small fires.
- Capacity : 9kg
- Accessories : Hanging and supporting unit
Automatic Extinguisher shall be provided for electrical control units
- Capacity : As per client interest
- Accessories : Wall or Roof mounting kits
Sand buckets
Buckets should be conical with round bottom base conforming to BS or equivalent standards.
Capacity of each bucket should be 9 liter.
Water extinguishers
Water extinguishers should confirm to BS or equivalent. The capacity of water extinguisher
should be 9 lit. The material used shall be plain water and a Carbon Dioxide cartridge to
provide the pressure. Dry chemical powder fire extinguisher – 5 kg /2 kg capacity Dry
chemical powder extinguisher should confirm to BS or equivalent. The capacity of the
extinguisher should be 5 kg / 2 kg capacity as applicable.
CO2 Extinguisher
CO2 extinguisher should confirm to BS or equivalent and must have test certificate from the
Explosive Dept. Capacity should be 4.5 kg.
1.8.10, HIGH VELOCITY WATER SPRAY SYSTEM (310)
A deluge system is a fixed fire protection system in which the pipe system is empty until the
deluge valve operates to distribute pressurized water from open nozzles or sprinklers.
Deluge systems are more complex than wet pipe and dry systems because they contain more
components and equipment. The deluge valve is activated by operation of a fire detection
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system installed in the same area as the spray nozzles. Various types of detection systems
may be used, including smoke and heat. The deluge system can be activated by a hydraulic,
pneumatic, electric, or manual release system or any combination of these release systems.
In our case an electrical actuation is selected. When the detection device is activated,
solenoid valve opened and the deluge valve is hydraulically tripped and water flows into the
piping system, discharging through all spray nozzles.
High velocity water spray system shall be provided where Transformers are located. The
additional water requirement shall be calculated and the same to be added in the fire water
tank. The system shall comprise of automatic deluge valve with strainer, test and drain
connections, high velocity nozzles, solenoid valves and annunciation panel. Some
transformers are proposed for distribution of power inside factory and others will be used for
export of power.
1.8.11, ELECTRICAL ( 311)

The electric supply to the pumping sets shall be entirely independent of all other equipment.
Even when the power throughout the premises is switched off the supply to the pumps shall
be continued to be available uninterrupted. The ratings and design of the motor and
switchgear shall confirm to the relevant standards specifications. The motor shall be of
continuous rating type and its rating shall be at least equivalent to the horsepower required to
drive the pump at 150 % of its rated discharge. The insulation of the motor shall be class E.
Cables for the motors and switchgear shall be armored.
Following electrical equipment are included the system:
 LV Power cable from Employer MCC to individual equipment in fire protection

system
 Motors for all drives
 Local Push button stations
1.8.12, AUTOMATIC FIRE EXTINGUISHERS (312)

Boiler Control room, Power house control room, Computer room, Telephone exchange,
technical offices, which house various electronic gadgets, are to be provided with Automatic
fire extinguishers, since these areas may be unmanned at times. These rooms shall be
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equipped with Modular type Halen substitute automatic fire extinguishers. These are small
extinguishers, which can be installed above the respective units to be Fire protected. The
principle of operation of the extinguishers is to sense the temperature of the unit below its
discharge head. When the sensed temperature exceeds the preset temperature, the glass bulb
bursts and directs the extinguisher charge to impinge on the unit that has to be protected. The
discharge point shall have a 90 0 cone to focus the impingement to put off the fire quickly.
Capacity of extinguishers range from 5 to 15 kg. The discharge time to be chosen should be
in the range of 3 to 8 seconds. The extinguisher should be rechargeable. These areas shall
also be provided with smoke detectors and alarm system.
1.8.13, FIRE ALARM (313)

Fire detection and alarming system for various areas included in the design
 Fire Detection units
 Fire alarm systems
 Alarm manual push button
 Siren
A public fire alarm unit shall have to be installed so that factory and residence colony can be
alerted in case of a fire. The system should be an electrically operated siren of effective
audibility over an area of 5 km radius. Sound of the siren should be different from factory
shift siren. The siren should be installed on highest structure in the factory. Areas of
maximum fire susceptibility are bagasse yard, molasses and oil storage and sugar go down.
The starters for the siren should be located in these areas; and at about 9 different places
including security office in the factory; so that it shall be easy for anyone to operate the siren
quickly on noticing a fire.
1.8.14, MOBILE FIRE FIGHTING UNITS (314)

Two mobile, truck or trailer mounted firefighting units, each fitted with water tank, pump
unit, hoses, and portable extension ladder 15 m long and ancillary equipment shall be
provided for the plant.
1.8.15, MISCELLANEOUS equipment (315)
The following equipment shall be stored at the fire station as a minimum requirement in
addition to the equipment and tools mounted on the mobile equipment.
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 5kg Dry Powder Extinguisher 10 pcs

 2kg Dry Power Extinguisher 10 pcs
 4.5kg CO2 Extinguisher 15 pcs
 9 kg Water gas Extinguisher 15 pcs
 9kg Sand Bucket 30pcs
 ½ “ x 15 m fire hose 24 pcs
 ½ “ water nozzle
 fire rescue suits
 proximity suits
 fire suits
 compressed air breathing apparatus
 gas mask
 ½ “ hose spanner wrench
 hydrant wrench
 fire axes
 two lb. shovels
 fire hook
 loudspeaker
 lighting equipment
 safety electric hand lantern
 CO2 recharging unit
 breathing air recharging unit
 powder extinguisher recharging tools
 ½ “ hand hose expander
1.8.16, SPARE PARTS (316)

1. Control Board Electrical Spares
2. Fire Detectors
3. Fire Alarm System Equipment‟s
4. Siren Push Buttons
5. CO2 Extinguishers
18
6. Dry Powder Extinguisher
7. Water/Gas Extinguisher
8. Automatic Extinguisher
9. Sand Bucket Extinguisher
10. CO2 cartridge
11. Spare for CO2 refilling equipment
12. Spare for chemical powder refilling equipment
13. Hydrant couplings
14. Deluge valve
15. Solenoid valve for deluge valve spray system
16. Low Pressure switches
17. High Pressure switches
18. Pressure gauges
19. Mechanical seal and spare kit for pumps
20. Sluice valves
21. Check valves
22. Pipe fittings/elbow, t-connection, reducer/
23. Seal for Fixed monitors
24. High velocity Spray nozzles for deluge valve system
25. Water level sensor
26. Water low flow switch
27. Spare kit for Generator Set
- Fuel Filter
- Oil Filter
- Pressure gauge
- Thermometer/Thermostat
19
- Control board spares
- ATS spares
28. Sight Glass for Fuel Day Tank
29. Network pipe gaskets
1.8.17, Applicable BS Standard (317)

Technical specifications of Fire Extinguishers and its associated equipment are to be as per
the Standards specified in the table below. Other equivalent standards will be acceptable.
Fire classification systems BS 4547
Fire glossary BS 4422
Fire alarms BS 5839
Fire alarms automatic BS 3116
Fire alarms glossary BS 4422 (4)
Fire detectors BS 5839
Fire detectors automatic BS 5445, EN54
Fire extinguishers on premises BS 5306 (4)
Fire extinguishers portable BS 5423, EN3
Fire extinguishers portable, Recharging BS 6643
Fire extinguishers portable, selection, Installation
and maintenance BS 5306 (3)
Fire hose reels BS 5306 (1)
Fire hose reels fixed installations BS 5274
Fire hoses couplings & ancillary equipment BS 336
Fire hoses non-percolating lay flat BS 6391
Fire hoses reel hoses BS 3169
Fire hoses rubber suction BS 3165
Fire hydrant indicator plates BS 3251
Fire hydrant on premises BS 5306 (1)
Fire hydrant systems equipment BS 5041
Fire hydrant underground BS 750
Fire safety extinguishing installations and
Equipment BS 5306
Fire sensitivity tests, automatic detection system BS 5445 (9)
20
Firefighting equipment on premises BS 5306
All above systems shall be adhere to the norms and regulations set out by Ethiopian
Government. All the necessary drawings and documentation shall be approved from the
concerned Ethiopian Authority. After commissioning the systems the certification from the
concerned authorities shall be obtained by the Contractor which supply and Install the
system. The Contractor shall organize the visit of Inspector for approving the system and
certification. List of equipment under fire protection system, brief description of internal
appliances, identification of sugar factory individual sections according to the class of fire
and brief description of each equipment is given in this Section.
* * *
21
2, TECHNICAL SPECIFICATION
Spec.
Particulars Unit Preferred Specification Detailed Specification
No.
301 Electrically driven pumps Lot 2
Type Vertical submersible
Capacity Cum/hr 273
Discharge pressure Kg/cm2(g) > 8.8 At 14 kg/cm2(g) flow rate 164
m3/hr
Working pressure range Kg/cm2(g) 8.8
Suction/Discharge mm 300/250 /Maximum Impeller length =
Opening 2.5 m
Pump Casing cast Iron CRITICAL/
Diameter of Pump NA
impeller
Material of impeller NA cast iron Shaft ss
pump speed rpm 1500
Pump efficiency % Minimum 70%
Motor Power kw 92kw
Totally enclosed, fan F Class
cooled/TEFC/
Wound class E Insulation
Windings vacuum impregnated heat and moisture varnish
motor working at 50 deg
ambient temperature
Pump Motor Power Curve Non-Overloading max Power at duty point
<=Max run out flow
NPSH 4.7 Subjected to change on
suppliers specification
Voltage available for V 400
electric motor
Common base plate
Flexible motor and pump with coupling guard
coupling
302 Diesel Engine Driven Lot 1
pump
Capacity Cum/hr >273
Discharge pressure Kg/cm2(g) 8.8 At 14 kg/cm2(g) flow rate 164
m3/hr
Suction Opening mm 300 /Maximum Impeller length =
2.5 m
Discharge opening mm 250 CRITICAL/
22
Diameter of Pump NA
impeller
Pump casing cast iron with internal coatings for
corrosion protection
Material of impeller Cast Iron Shaft ss
pump speed rpm 1500
Pump efficiency % Minimum 70%
Pump Power Curve Non-Overloading max Power at duty point
<=Max run out flow
NPSH 4.7
Motor Power kw 92
Speed and HP of engine rpm & HP 1500/120kw
Pump drive gear box Mounted gearbox bolted directly Separate generator/optional/
coupling to fly wheel
Pump at 90 deg.
Mounting frame Heavy duty galvinized and Integral fuel tank and lifting
painted lugs
Generator Fuel lit/hr approx. 150
Consumption
Fuel day tank capacity lit 1500
Dimension L=2m, H=1.6m, W=1.4m
Ignition type Compression type
Fuel used Diesel
Diesel Engine Control ATS function
Oil low pressure warning Oil pressure gauge
Low speed warning
Low cooling water level warning
High cooling water temperature Temperature gauge
warning
Exhaust temperature control
gauge
PLC automation
Pump housing Ventilation duct for generator If one generator used/if
multiple wall opening
Exhaust pipe Stainless Steel
Turbo Charged Yes
303 jockey Pump Lot 1
Capacity Cum/hr 10.8
Discharge pressure Kg/cm2(g) 8.8
Suction/Descharge mm 63
23
Opening
Strainer Details basket type, cast iron body, SS
basket
Diameter of Pump approx. 150mm Subjected to change based on
impeller suppliers specification
Material of impeller Stainless Steel
pump speed rpm 2900
Pump efficiency % 75%
Motor Power kw 6
Motor Type Vertical/multistage/centrifugal
Voltage available for v 400
electric motor
Additional Accessories
Required
Strainer Details basket type, cast iron body, SS In jockey pump suction line
basket
Pressure Switches High Pressure Switch Shut off head at 1.2 times
maximum set pressure
Discharge-Low Pressure Switch Start jockey Pump operation
Discharge-Low/Low pressure Start Electrical Pump
Switch operation
Flow Switch Suction Low Flow Stop Pumps Operation
Pressure gauge At Discharge Lines With stope cocks
Vibration damper 4 no. At Discharge line of each 3 no. 250mm/1 no. 63mm
pump
Check Valves for high 4 no. At Discharge line of each 3 no. 250mm/1 no. 63mm
pressure application pump
Sluice gate Valve Suction Diameter: 300mm
Discharge: 250mm
Foot Valve 300mm
Collection manifolds Suction-250mm
Discharge-250mm
Automatic air release 1 unit
valve
Flow meter OPTIONAL
304 hydrant System
Type carbon steel screwed down/oblique down
IS 1239 part 1 upto 150NB
IS 1239 part 1 above 200NB
no. of single headed no. 76
hydrants
24
no. of double headed no. 14

hydrants
no. of upper floor no. 6
hydrants/risers/
Hydrant network pipe mm 250
diameter
Length of Hydrant pipe m 3100 to 3400
network/250 mm/
Length of branching pipe m approx. 150m
to HVWS/80 mm/
Isolating valve for HVWS 80 mm/3''/

Branch line
Qty no. 7
Sluice valve/Gate Valve/
for hydrant network
Qty 41
Nominal Pressure bar 16
Test Pressure bar 21
Body/Disk/Cover Ductile Iron/cast iron
Seat Gun metal
Stem Stainless Steel
Stem Nut Gun metal
Stem seal EPDM
Gasket Compressed asbestos fiber
Gland/gland cast iron
packing/stuffing box/hand
wheel
Air release valve with
isolation valve
Breeching Inlet Included
Are the couplings Y/N Y
interchangeable?
No. of pressure gauges in no. Equivalent to each hydrant
the system system
Range of pressure gauges Kg/cm2(g) 0 to 20 or max
in the system
Type of pressure gauges Dial Type larger dial size/glycerin filled/SS SS ring
polished body
No. of Pressure switches No. 4
number of gate valves in no 5 no.(2*63/3*250) for pump station
25
the pump house

Sizes mm 250 for hydrant main piping
system
Number of non-return no. 4 for pump station
valves
Sizes mm 63/250/250/250
Wrapping and coating of To be Included
underground pipes
Holiday Test after Will be performed
commissioning
305 Hydrant and Fixed
Monitors
Single Head Hydrant
Qty no. 76
63mm female instantaneous
coupling outlet
valve right angle
material: Gun metal Subjected to change
Inlet: Screw down
Downward Oblique
Capacity: 57m3/hr
Maximum working Pressure: 13
bar
Inlet Base Flange for one head: One pressure regulator
80mm
Outlet: 63mm
Blanck cap 63mm male instantaneous
With chain and knob type
Double Head Hydrant
Qty no. 14
63mm female instantaneous
coupling outlet
valve right angle
material: Gun metal Subjected to change
Inlet: Screw down
Downward Oblique
Capacity: 57m3/hr
Maximum working Pressure: 13
bar
Inlet Base Flange for two heads: Two pressure regulators
110mm
26
Outlet: 63mm
Blanck cap 63mm male instantaneous
With chain and knob type
Fixed Monitor no. 12 Construction detail to be given
Recommended working
Pressure: 7 bar
Maximum working pressure: 12
bar
Test Pressure: 24 bar
Flow rate: 2000 lit/min at 7 bar
Horizontal throw: 35-50m
Vertical Throw: >30m
Horizontal Rotation: 360 deg
Vertical Rotation: +85 deg, -45
deg
Base Flange/Threaded: 4''
Outlet: 63mm
Locking arrangements
carbon steel water ways
Jet/Spray Nozzles
Swivel Joints
handle bar
Threaded inlet
Stand Post type
M.S. Seamless pipes
Stand Posts
Single head Hydrant mm 80 mm
Double Head Hydrant mm 110 mm
Hydraulic Pressure Kg/cm2(g) 23
Tested
material MS pipe
Hydraulic Pressure Kg/cm2(g) 23
Tested
Isolating gate valve for

fixed monitor
Qty
Size 110 mm
306 Hose pipes and nozzles
27
material Synthetic woven jacket rubber

lined/fire resistant
Diameter mm 63mm
Make Shall be provided
Bursting Pressure kg/cm(g) 35 Abrasion resistance: 200 cycle
Test pressure kg/cm(g) 21 Heat resistance: 12 sec
No. of lengths Light alloy branch pipes
1 x 15 m 76
2 x 15 m 14
Diameter of nozzle end mm 32 63mm coupling instantaneous
male coupling
Make Aluminum alloy
Nozzle quantity no. 104
Make NA
307 Fire Extinguishers
DRY POWDER
EXTINGUISHERS/2kg
no. of Dry chemical no. 152
powder/DCP/
Type Sodium bicarbonate/mono-
ammonium phosphate
Capacity lit 2
Height mm 370
Cylinder Diameter mm 112
Overall width mm 150
Filled weight kg 3.6
Range of throw m > 2m
duration of discharge sec 10
Working Pressure at 20 bar 15
deg c
ambient temprature deg c < 60
Internal Sodium Potassium Bicarbonate
bicarbonate/monoammonium
phosphate
DRY POWDER
EXTINGUISHERS/5kg
no. of Dry chemical no. 60
powder/DCP/
Type Sodium
phosphate
28
Capacity kg 5
Height mm 500
Cylinder Diamter mm 160
Overall width mm 300
Filled weight kg 8.5
Range of throw m > 4m
duration of discharge sec 13.5
Working Pressure at 20 bar 15
deg c
ambient temprature deg c < 60
Internal Sodium Potassium Bicarbonate
phosphate
CO2 EXTINGUISHER
No. of Co2 Extinguishers no. 70 Class B
Type CO2 as extinguishing agent Flammable liquids
Capacity kg 4.5 Outdoor fires
Specification
Working Pressure at 20 60 bar
deg c
Body material Steel
Test Pressure 250 bar at 20 deg c
Burst Pressure 450 bar
Operating temprature up to 60 deg c
Height approx. 700mm
Cylinder Diameter approx. 150mm
Overall width approx. 300mm
Range of throw approx. 4m
Duration of Discharge approx. 14 sec
Filled weight approx. 11 kg less weight in hot areas
Internal CO2
WATER/GAS FIRE
EXTINGUISHERS
No. 70
Capacity 9 lit Wood/paper/plastic/coal/fabric
Prissurizing system carbon Dioxide cartridge not used in electrial eqpt
Height 600 not used in flammable
Cylinder Diameter 189
29
Filled weight 14
Range of throw m >4
Duration of Discharge sec 50
Working pressure bar 10 to 15
ambient temprature deg c <60
Internal media water/compressed air
Internal lining Polyethyline lining
308 High Velocity water Spray Lot 7
System
Sprinkler spray water For 7 transformers
system
Capacity of System lit/sec 1.5
Size of piping connection mm 3/4 ''
to nozzle
pressure gauge reading at Kg/cm2(g) 7
delivery step valve
Maximum working Kg/cm2(g) 12
pressure
Sprinkler Head 90 deg.
UL listed
3/4 '' NPT
Qty of sprinkler head no. 220 /recommend/
Maximum velocity of m/sec 3
water
Water Spray angle deg 90
Weight of spray nozzle kg 0.2
Radius of coverage/each m 2 at 4m height
nozzle/
Deluge valve assembly Automatic Deluge
3''
wet pilot trim
electrical trim
manual release
water proof alarm Gong
pressure switch
pressure gauge
UL Listed
Actuation 24 DC Electrical/solenoid valve/
Annunciation panel
30
Detection Heat detection Type to be forwarded by

supplier
Qty of heat detector 14 Subjected to change if
transformers installed outdoor
Gate Valve 3 ''
Y - Strainer 7
3 ''
Drain Valve 7
1 ''
Control By central fire alarm panel Recommend if separate
dedicated panel required
Sounder 7
309 Electrical Lot
LV panel for electrically
operated pumps
cable for electrically
operated pumps
Earthing system for Available
electrical operated pumps
List of Instrumentation RCC tank level sensor
low pressure switch at jockey
descharge
high pressure switch at pumps
descharge
Low pressure at pumps inlet
Timer switch for electrical pump
start/optional/
Smoke detector at various
locations
Heat detector at various locations
Low flow switch at pumps
suction
Fuel day tank level control
generator sets instrumentation
310 Automatic Fire Lot
Extinguisher
No. no. 14
Type of automatic mild steel construction
extinguishers
ABC/Halotron 1 filled
Modular type
Temprature sensing glass bulb/68
31
deg c
Discharge cone at 90 deg
Rechargeable
Roof mounted
15 bar: Super charge Pressure
Pressure gauge existing
Sprinkler Automatic release and gas tight
Nozzle 99% discharge
Type 1 - capacity kg 5 Qty: 5
maximum Volume m3 8.7
protected
Height mm 230
Diameter mm 230
Gross weight kg 8
Disharge time sec 3 to 8 sec
maximim Volume m3 17.5
protected
Height mm 260
Diameter mm 300
Gross weight kg 15
maximim Volume m3 29
protected
Height mm 260
Diameter mm 400
Gross weight kg 8
311 Fire Alarm
Electrically operated siren Y
at 5 km radius
No. of places alarm to be no. 9
installed
Fire Detection and Alarm
Systems
Smoke Detectors no. 94
Heat Detectors no. 3
32
MCP/Manual call Point/ no. 156

Sounder no. 156
Annuciation panel/Fire no. 1
alarm panel
Single Input/output no. specify
module
3A power supply no. 7
Zonal short circuit loop no. specify
isolator
Hand held programmer no. 1
other accessories specify
Detectors in HVWS 7/for each transformer/ High velocity water spray
system systems
312 Mobile Fire Fighting Unit 2 Mobile Truck
Units
With Four wheel drive
Stationary pump and mobile
pumping system
Fire Truck water Tank lit 5000-6000 lit
capacity
Tank material SS
Pump type Centrifugal
Pump rating lit/min 2000 approximate
Pressure at specified bar 10
rating
Maximum working height m 60
Pump drive To be specified
all wheel drive Yes Four wheel drive
Power transmission Split shaft transmission/power To driving wheels and main
divider/ pump
Fire pump main Pump For stationary pumping
High Pressure Fire Pump Ultra High Pressure System For mobile attack
50 LPM at 40 bar
Fixed Monitor 2,000 LPM/Manual Operated/
Hose Reel 1.25'' x 30 m/Manual rewind/
Accessories Pump control Around the engine
Breathing apparatus
Hose Reel and fittings
Nozzles
Hose roller
33
Rolling Shutters
Tank material Steel Anti corrosion treated
Control and gauges hand throttle
Pressure gauges
Automatic Shut down
Valves
Suction 2 x 80mm
Discharge 2 x 63mm
Priming valve handle manual
Discharge valve handle manual
Suction valve handle manual
Pump and plumbing Drain yes
Tank to plumbing shut off yes
Gravity Tank Drain yes Pipe Plug Type
strainer Yes Inlet Screen
Horsepower rating HP Approx. 240
Engine fuel type Diesel
Steering Left
Cabin Double Cabin
Pipe & accessories specification

S.No U/M Qty Specification Remark
1 Hose Box/900*600*250/
Quantity no. 14
Type Self-Standing Type with
Pole
material Mild Steel
Size mm*mm*mm 900*600*250
Double Door
Glass door
Fire Red Color
Nozzle inside Box 2 1/2 ''
aluminum alloy
Qty of nozzle
34
Qty of Hose 2 hose per each box
Size of Hose 2 x15m for each box

2 Hose Box/750*600*250/
Quantity no. 76
Type Self-Standing Type with
Pole
material Mild Steel
Size mm*mm*mm 750*600*250
Double Door
Glass door
Fire Red Color
Nozzle inside Box 2 1/2 ''
aluminium alloy
Qty of nozzle
Qty of Hose 1 hose per each box
Size of Hose 1 x15m for each box

1 x 30m for each box
type Steel bucket/round bottom,
red painted
3 Sand Bucket
No. of Sand Bucket
Capacity kg 9
Accessories Hanger and fixing items
4 High Velocity water Lot 7
Spray System Piping
Type of Piping and HDPE below ground
Fittings
GALVANIZED PIPE
above ground
Fittings
Elbow Included
T-Connection Included
Union Included
Reducer Included
Nipple Included
Socket Included
35
Adaptor Included
Pipe Support System Included
5 Piping for Fire Hydrant
Network
Type of piping and HDPE Pipe
fittings
Fittings
Elbow Included
T-connection Included
Reducer/10'' to 3''/ Included
Socket Included
4 Lighting/Illumination/ Shall be provided Vapor proof
incandescent lighting
For pump Station
Housing
Cable
Lighting Board
Cable Tray and PVC
Trunk
Breaker and other
accessories
Support work
Fire Detection and Alarm System

No. Factory Section Smoke Detector Heat Detector MCP Sounder
1 Technical Office 42 6 6
2 Mechanical workshop and store 9 3 3
3 Process House 65 65
4 Sugar Go Down 8 8
5 Lime Station 7 2 2
6 Ion Exchange Plant 7 2 2
7 Diffuser 10 10
8 Mill House 8 8
9 Boiler area 10 10
10 Bagase yard 4 4
11 Power House 5 5
12 Molasses Storage 2 2
13 Demineralization Plant 2 2
36
14 Transformer HVWS 7 7
15 ETP 4 6 6
16 PWS 6 10 10
17 Fire Pump House 9 2 2
18 Diesel Generator area/House/ 3 2 2
19 Chemical Store/Not indicated/ 10 2 2
94 3 156 156
Qty Comment
20 Electrical operated siren/5km/ 1 At highest elevation of the factory
21 Manual push button for siren 9 at 9 different locations
22 Fire alarm control Panel 1 No. could vary on manufacturer specs
23 Single Input/Output module Specify Based on manufacturer's control unis
23 3A power supply 7 For each transformer unit solenoid valve
24 Zonal Short Circuit Loop Isolator Specify Based on manufacturer's control unis
25 Hand help programmer 1
26 Other accessories Specify
Assumptions: ** Smoke Detectors are dedicated only to offices, administrative buildings, workshop, store
Where there is significant human intervention
** Smoke detector in factory areas could be included if no significant cost incurred
** Beam detector is not critically required for the factory
Portable fire extinguisher
No Factory section Area Co2 Dray Dray Water/gas Automatic Sand
powder/ powder/ extinguisher Bucket
5kg 2kg
1 Technical Office 2720 m2 4 8 4 10 1 195
2 Mechanical workshop 3000 m2 6 7 4 1
and store
3 Process House 16,600 20 28 22 3
m2
4 Sugar Go Down 7800 m2 18 20
5 Lime Station 572 m2 1 2
6 Ion Exchange Plant 728 m2 1 2
7 Diffuser 3865 m2 2 6 6 1
37
8 Mill House 2860 m2 2 4 4 1

9 Boiler area 1115 m2 4 12 12 1
10 Bagase yard 13,000 32
m2
11 Power House 2240 m2 10 8 8 1
12 Molasses Storage 6963 m2 12
13 Demineralization approx. 1 2 1
Plant 500 m2
14 Transformer 7 rooms High Velocity Water Spray
System to be Deployed
15 ETP 600 m2 8 3 1
16 PWS 500 m2 6 3 1
17 Fire Pump House 150 m2 1 1 1
18 Diesel Generator 4 2 1
area/House/
19 Chemical Store/Not 2
indicated/
Total 70 152 60 30 14 195
Assumptions:
** CO2 Extinguisher is used only on inflammable areas and electrical items
At each electrical driven units/ motors, pumps…/
Recommended to use outdoor to avoid suffocation
** Dry powder could be used in process area and chemical storages
For office area: unit/300 m2
For process area: unit/400 m2
** Water/gas not recommended on Flammable liquids and chemicals.
Used in offices and product areas
** Automatic Extinguishers only used on Electrical control /computer server rooms
* * *
38
3. Erection and Commissioning Methodology

3.1. Activities
Verification of Input material handling/Items to be erected/

Verification of Manpower allocation
Erection and Installation follow up
Progress Report
Quality assurance
Testing and Inspection
Shop Test
Welding
Commissioning at site
Tools and tackles
Verification of Consumables
Verification of Compatibility of items
Overall
3.1.1. Verification of Input Material handling /Items to be erected/
Includes;
 Unloading from load carrier at project site

 Stacking
 Verification
 Record specification against requirement
 Record keeping on delivered items
 Transportation from store to erection site
 Examine package on arrival
 Bring notice of the client for any loss & damage
 All materials stored as per manufactures recommendation
 Apply preservative on equipment in store during storage, erection &commissioning
 Materials stored in sleepers so that it does not torch the ground
 Immediate replacement of damaged items
39
3.1.2. Verification of manpower allocation
 No. of personnel to involve in the project activity

 Qualification of personnel
 Role and Responsibility including delegation
3.1.3. Erection/Installation
 Check the various equipment foundations for correctness with respect to level,
orientation, dimensions etc. before erection
 Erection of equipment carried out as per quality plan
 Necessary protocols & records for inspection observation shall be maintained on the
form provided
3.1.4. Progress reporting of erection work
 Monthly progress report

 Manpower report
 Material report
 Other reports considered necessary
3.1.5. Quality assurance
 Ensure the equipment & services at site or other places of work one in accordance
with specifications
 Supplier/contractor should adopt the suitable quality assurance standard development
by client
 A quality assurance progress shall generally cover the following
 Contractor‟s organizational structure
 Qualification data of the key personnel
 Verification of material purchased
 Material source inspection
 Ship manufacturing
 Site erection controls including fabrication & assembly control
 Calibration & testing of measuring &testing equipment
 Welder & welding procedures qualification
40
 Weld / repair procedure actual to be used during fabrication to be verified

 Non- destructive examination result report
3.1.6. Testing & inspection
 All equipment‟s under the scope shall be subject to inspection & tests
 The cost of all tests shall be borne by supplier/contractor
 The supplier / contractor shall prepare quality plane in two sections, on for quality
control at shop &the other for quality control at site. The supplier/contractor shall
finish the quality plan for shop activities indication stage-wise all tests & inspections
to be carried out went from raw materials stage, manufacturing assembly,
performance & final inspection
 Any test necessary from operation, safety &reliability point of view shall be included
 The contractor / supplier shall finish the quality plan indicating all tests & inspection,
procedures & acceptance norms to be adopted for assuming quality for each piece of
equipment under this specification from the receipt of material at site, during storage,
erection, pre-commissioning to final &commissions of the plant
 Preservation
 Pre-assembly
 Alignment
 Position of equipment
 Foundation preparation
 Grouting
 welding / bolting
 heat treatment
 non-destructive examination
 hydraulic test
 performance test
 all fabrication, manufactured items (including any proprietary items) motors, gears,
gearbox, fans, switches etc…,shall be subjected to stage-wise inspections & tests at
the manufactures workshop before dispatch
 pressure vessels shall be inspected by appropriate authorities at the sites as well as at
shop
41
3.1.7. Shop test
 Include all tests to be carried out at contractor‟s workshop, at workshop of sub-

contractor & at works where raw material used for manufacture of the equipment
 Such tests shall include electrical, mechanical, performance & hydraulic tests
 All material shall be of tested quality, supported with duly correlated test certificates
3.1.8. Welding
 All welding procedures adopted for performing welding work shall be qualified in
according with the requirements of section 1*of ASME or any equivalent code
 These welding procedures shall clearly state the type of material, thickness, the joint
details, the repent temperature maintained, the post weld heat treatment given, the
welding current & voltage used during qualification of welding procedures
3.1.9. Commissioning at site
 Dry run of driven units with coupling & any connecting pipes unbolted & drives then
checked for correct rotation
 Pressure tests of all piping
 Running tests of all machines shall be executed
 Amperes of electrical driven units
 All machines shall run for 30 minutes on no load except pumps
 Pumps should run 30 min with water should not this possible, the
pumps will not be test run
 Oil & greases will be flushed out after 1st fill
 All unpressurized tanks & vessels, shall be filled with water for test
 Pipe runs shall be done with free ends to clear of foreign materials
 Tank vessels drain lies & strains shall be opened, cleaned of foreign material.
Instrument airlines shall be pressurized to the full air pressure & soap bubble or
similar tests to be done.
42
3.1.10. Tools and tackles
All the necessary tools and tackles for erection activity should be availed/List of Tools
and Tackles to be attached with this document/
3.1.11. Verification of Consumables
Supplier should provide all consumable required for erection, commissioning &
testing. Storage of electrodes will be done in control humidity room as per
manufacturer‟s recommendation Supplier submit a list of oils & lubricants of
approved grades & type & also recommend the quantity required for operation of one
complete season shall provide 110% of all lubricant, oils & greases required for the
initial filling
3.1.12. Verification of Compatibility of Items
System compatibility of all items and either from the same supplier of different
suppliers should be verified.
3.1.13. Overall
 Dimension & quantity checks

 Conformal of specification
 Hydraulic test of tanks, vessels, pipelines etc...
 Mechanical tests on rotating machinery like pumps etc…
 Standard running tests on rotating mechanical & electrical machine
 Measurement of surface temperature of insulation
 Project report shall indicate the progress achieved against planned with reason
indicating delays if any &corrective measures to make good slippage of lost time
 The manpower report shall indicate the manpower deployed category wise daily
specifying also the activity in which they are deployed
 Progress review meeting shall be attended by the contractor to discuss the schedules,
programs & action taken to achieve the progress.
43
4. Instrumentation, Automation &Control Philosophy

4.1. FPS Instrumentation
FPS Instruments used for the system
Water Storage Tank Low level sensor(LLS)
FPS Pump House Analogue Flow Meter/FM/
Low level sensor (LLS)

Fuel day tank
High Level Sensor/HLS/
Jockey Pump Discharge High Pressure Switch/HPS/
Electrical Driven Pump Discharge High Pressure Switch/HPS/
Diesel Driven Pump Discharge High Pressure Switch/HPS/
Priming Tank Low Level Sensor/LLS/
Analogue Pressure gauges

FPS Pump House
Ai each pump Discharge/
4.2. FPS Automation
FPS control panels are designed to control system function automatically. Relay controls to
be deployed.
4.3. FPS control philosophy
4.3.1. Water storage tank level control
Single level control float sensor used in the water storage tank to control the minimum level
of water (LLS). The level sensor senses the minimum level of the water in the storage tank
and gives signal to the plc panel then in response of the signal gives indication in the form of
light and alarm. When the level sensor sense low water level in the tank the plc panel control
44
the FF pumps not to operate till the water level in the tank rises. The pump will be a standby
position when the water level recovers.
4.3.2. Pump ON/OFF Control (operation control)
The fire water pump system provided with automatic starting facilities which will be
activated for any of the following cases
 When the fire water ling main pressure is low-low.

 Local manual start (MCC Panel).
The fire water ling main pressure is always maintained by the jocky pump that starts
automatically when the fire water header pressure is low and stops when the fire water
pressure is high.
For any reason, if the fire water ling main pressure falls down to 6.5 bar the duty fire water
pump failed to start or nor able to develop the required pressure and the ling main pressure
continues to drop to 6 bars, the standby diesel driver pump will start automatically. Pumps
can also be started manually from the pump local control panel.
4.3.3. Flow Meter
The flow sensor is mounted on the outlet (discharge header) of the fire pumps. It measures
the flow rate of the outlet of the water (analogue reading will be sufficient and no signal to be
sent to the control panel).
4.3.4. Fuel day tank level control
Three level control float sensor used in the fuel day tank to control the level of water (LLS,
MLS, and HLS) the level sensor senses the medium level of the fuel in the day tank and gives
signal to the PLC panel. The plc panel then in response of the signal gives indication in the
form of light and alarm. When the level sensor senses low fuel level in the day tank the plc
panel control the diesel engine not to operate till the level in the day tank rises. The diesel
operator will be in a standby position when the fuel level recovers to medium level. When the
level sensor senses medium fuel level in the day tank the plc panel control the fuel inlet pump
to be switched <ON> to recover the level in the tank to HL.
45
4.3.5. Pressure Control Switch
Pressure switches installed at discharge sides of all pump to the operation of pump as
specified above.
4.3.6. Pressure gauge
Analogue pressure control gauges installed at each pump discharge lies to indicate the actual
pressure in the system.
4.3.7. Priming Tank level sensor
Single control float sensor used in the primary tank to sense the level of water (LLS). The
level sensor senses the low level in the primary tank and gives signal to the plc panel. the plc
panel then in response of the signal gives indication in the form of light and alarm.
***
46
5. Equipment Manufacturing Checklist

5.1, Piping
5.2, Mechanical Items
5.1.1. All materials
5.1.2. Forging
5.1.3. Casting
5.1.4. Foundation Bolts
5.1.5. Fasteners
5.1.6. Gaskets/Diaphragm
5.1.7. Gear Units
5.1.8. Valves
5.1.9. Strainers
5.1.10. Pumps
5.3, Electrical Items
5.4, Instrumentation
5.5, Painting
5.1 PIPING
Piping shall be according to the NFPA standard or equivalent. Carbon Steel or
HDPE pipe could be used for fire Hydrant network. Valves and fittings will
preferably be of same make and of modular design so as to facilitate interchange-
ability and reduction in variety.
Suitable drains, vents, valves, shall be provided in the pipelines wherever necessary.
All Carbon steel pipes and pipe fittings used for conveying the effluent shall conform
to BS or other equivalent standard specifications listed elsewhere in this document.
The piping shall be Class 'C'. The thickness of Carbon steel pipes, having diameter
more than 200 mm shall, be 8 mm minimum. In case of all piping above 25 mm NB
only flanged joints shall be used. All flanges shall conform to BS or other standard
Specifications. The distance between two flanges in straight portion of pipes shall not
exceed 6 meters. In case of bends, flanges shall be provided at least on one end.
Flanges at ends of pipeline shall be provided with bolted blind flanges.
47
5.2. Mechanical Items

5.2.1. Materials
All materials supplied shall be new, and workmanship shall be of first class quality
and shall comply with the appropriate British or other International Standards, and in
the absence of such standards shall be of tested commercial quality. All steel materials
shall be free from laminations, folds and cracks. Any materials not fully specified in
the particular specifications and which may be supplied shall also comply with above
conditions.
5.2.2. Forgings
Forgings shall be free from all defects affecting their strength and durability,
including seams, pipes, flaws, cracks, scales, fins, porosity, hard spots, excessive non
metallic inclusion and segregations. All finished surfaces of forgings shall be smooth
and free from tool marks. Tool marks or tearing of metal by the finishing tool will not
be accepted on the surface of the fillets and such marks, if they occur, shall be
removed by grinding or finishing. Heat number shall be stamped on all forgings at a
place clearly visible after the forging is assembled in a complete unit. Forgings above
150 mm diameter shall be subjected to internal examination for detection of flaws and
to heat treatment for relief of residual stresses.
5.2.3. Castings
All castings shall be of fine grain quality and shall conform to the relevant BS or its
equivalent specifications. The surface of castings which do not undergo machining,
particularly those of steel or iron in contact with water shall be dressed smooth in the
foundry with all joints blended into the adjacent surface. The castings shall be free
from foundry irregularities, such as projections, ridges, hallows, honey combing, pock
marks, blow holes and cracks or chip marks, so that they will not require surface
smoothing operations prior to painting. All cast materials shall be as free as is
practical of blow holes and flaws. No welding plugging or filling of any defective
parts shall be done. No defective castings shall be accepted. Heavy steel castings shall
be rough machined and then normalized by heat treatment before finish machining.
5.2.4. Foundation bolts
48
Foundation bolts, holding down bolts, rag bolts with nuts and washers for all the
equipment of the Plant, structure etc. are covered under the Contract, shall be supplied
by the Contractor. Wherever required grouting pads shall be supplied.
5.2.5. Fasteners
All screws, bolts, nuts and studs shall be of international standard (metric) form of
threads. Bolt heads and nuts shall be hexagonal. Hexagonal recesses shall be provided
in the head of counter sunk head bolts and machine screws. The bolt length shall be
such as to ensure at least two full threads are projecting after the nut has been
tightened. Nuts and Bolts for pressure containing parts shall be of approved, high
quality steel machined on the shank and bearing faces of the head and nut. Where
there is a risk of corrosion, bolts shall be finished flush with the top of the nut and the
bolts and nuts shall be corrosion resisting steel or bronze. All nuts shall be provided
with washers, parallel or taper as appropriate. Where ever there is a possibility of nuts
becoming loose due to vibration, mechanical locking devices of approved form shall
be provided. Spring type washers shall not be permitted where these washers may
damage any protective coating. Special locking compounds may be used as an
alternative to mechanical devices subject to the Employer's approval. In case of screw,
nuts, springs, pivots etc. for instrumentation the use of iron and steel shall be avoided.
Steel screw when used shall be zinc, cadmium or chrome plated. When painting is not
possible owing to tolerance limitations, it shall be of corrosion resisting steel.
Instrument screws (except those forming part of a magnetic circuit) shall be of brass
or bronze. Springs shall be of non rusting material, eg., phosphor bronze or nickel
silver as far as possible. When fitting on outdoor equipment all bolts, nuts and
washers shall be of non-rusting material when in contact with non-ferrous parts.
Where fitted bolts are used there shall be a driving fit into the reamed holes they are
to occupy and be marked to ensure correct re-assembly on Site. The threaded portion
of such bolts shall be of a diameter that shall prevent damage to the thread on
assembly. All nuts, bolts, fasteners required for assembly or mounting of any
equipment of the Plant procured through these documents, including foundation and
holding down bolts, are to be included in the supplies.
5.2.6. Gaskets, Diaphragms
49
Rubber or rubber-based materials shall not be used for gaskets, diaphragms, etc.
Instead, synthetic materials, not subject to deterioration due to climatic conditions
shall be employed. The supplier shall include for supply of all gaskets required for
jointing of pipe flanges, and sealing of mating faces. Generally specifications of
gaskets for different duties shall at least be equivalent to the following:
d) For air ducts: wire woven asbestos gaskets, 6 mm thick.

f) For Effluent piping: wire inserted synthetic rubber gasket, 3 mm thick, resin cured
to withstand temperatures up to 70 0C.
5.2.7. Gear Units
Unless otherwise stated in the particular specification, all gear units for reducing or
increasing speed of a prime movers, shall be of the totally enclosed type with casing
cast in suitable materials and containing gears rated in accordance with British
Standards or other equivalent standards. All gearboxes shall be designed with
minimum 1.7 service factor as per AGMA rating unless stated otherwise. All
gearboxes above 25 hp shall be helical type. The gears shall be mounted on steel
shafts running in ball or roller bearings unless otherwise specified. As applicable to
duty the gear case shall incorporate an integral type of anti-runback gear. The gear
case, bearings and couplings shall be as detailed in the particular specification. Speed
ratio of worm reduction gears shall not be more than 50/1.
5.2.8. Valves in piping

Valves shall be provided in each branch line. Suction and delivery lines of all pumps,
shall be provided with isolating valves. Delivery lines of all pumps shall be provided
with non-return valves. Non return valve shall be installed between pump delivery
flange and isolating valve.
5.2.9. VALVES
Valves on 2.6 bar (a) and below steam pressure and live steam piping (if required)
shall be as per Class 150 of ANSI Standard steel pipe flanges, flanged valves and
fittings. Valves and fittings should preferably be of same make and of modular design
so as to facilitate interchange-ability and reduction in variety.
50
All valves preferred to be sluice type with post indicator.. Valves shall be installed so
that any plant item may be isolated from all services and process lines and to allow
tanks and vessels to be drained and vented. Valves shall be supplied in order that
standby pumps may be serviced during normal factory operations. Valves in
infrequently used pipelines shall be positioned in such a manner as to avoid piping
remaining filled with fluid for prolonged periods of time.
In addition, special duties shall have valves considered most suitable for those duties.
Non-return valves, relief valves, ball float valves, bib nose test cocks, drain cocks,
etc., shall be provided as considered necessary for the efficient functioning of
equipment of the Plant and to facilitate repair work and maintenance.
5.2.10. Strainers
In-line pot strainers shall be provided at all points where it is necessary that the solids
in the fluid may otherwise damage the equipment. The pot strainers shall be efficient
and manufactured as per relevant BS or its equivalent code. Strainers shall also be
provided on the suction side of the pumps as detailed in the particular specification
and as per relevant BS or its equivalent code.
5.2.11. PUMPS
The head/flow characteristics of pumps shall be such that the head continuously rises
with decreasing capacity until a maximum head is reached at zero flow. Maximum
run-out flow should be at least 130 % of duty point flow.
The shut off head should be at least 1.1 times the duty point head and should not be
more than 1.2 times the duty point head.
The power curve should be non-overloading type with the maximum power occurring
at or near duty point or towards maximum run out flow. NPSHR curve should be
continuously rising in the range of operation, from the minimum flow to the
maximum flow in the range. Required NPSH values shall not exceed available values
over the entire range from minimum to rated flow. The efficiency curve should be
fairly flat in the range of + 1 % of the Best Efficiency Point (BEP) flow.
The duty point of the equipment should preferably lie in this flat region. Unless
otherwise stated, except for boiler feed water pumps, in the particular specification,
51
all centrifugal pumps shall run at speeds not exceeding 1500 RPM. Maximum
efficiency of the pumps shall be at 70-80% rated load.
Supplier should deliver the following data:
a) Fluid to be pumped
b) Type of pump (e.g. split casing centrifugal)
c) Rotational speed
d) Impeller diameter
e) Power consumed and motor size
f) Materials of construction of :
i) Casing
ii) Impeller
iii) Shaft
iv) neck ring
v) Bushes
g) Quantity of fluid to be pumped
h) NPSH required
i) Total net pumping head from all causes.
j) Bearing type and number.
For all pumps the following characteristic curves shall be furnished:

a) Capacity against head
b) Capacity against efficiency
c) Capacity against power consumption
All pumps are to be supplied with water sealed packed glands or mechanical seals
unless otherwise specified. Where fluid pumped is water this may be fed from the
pump discharge into the gland. All centrifugal pumps shall be supplied fully
assembled and aligned with electric motor and shall be complete with coupling,
common base plate, sole plates, coupling guard, holding down and foundation bolts.
Wherever required grouting pads shall be supplied.
All positive displacement pumps shall be supplied with driving motor, gearbox,
couplings, base plate, and sole plates for complete pump with drive assembly
52
coupling guards, holding down and foundation bolts. Wherever required grouting
pads shall be provided.
5.3. ELECTRICAL EQUIPMENT

3 Phase AC 400 V Power shall be available for factory power supply. Power
distribution cables will be installed from factory Power Supply to FPS MCC and
from FPS MCC to individual motors.
These shall be including but not limited to following:
- Electric motors
- MCC
- Cable from PCC to MCC & Cable trays
- MCC to individual motors
- Starters / Push button for each equipment/motor/item
- LT Cabling & Wiring interconnecting all above
- Panel stand for individual starters
- Earthling
- Illumination at ETP
5.3.1. General
All electric motors with IP55 protection for outdoor and IP54 for indoor applications,
400 V having insulation Class F and temperature rise limited to Class B and all main motors
complete with 230 V internal heaters for rating above 30kW and shall conform to
IS:325/IEC60034. All cabling shall be of Copper conductors; Cabling to be carried on
suitable cable racks or in metal conduits and protected from risk of fire.
- Local push button starters with IP55 protection for outdoor and IP54 for
indoor applications for all drives.
- All the motors shall be of „energy efficient‟ (EFF1 range) type and shall meet
the following requirements:
- No Aluminum or its alloys shall be used for the manufacture of the
motors and/or components and accessories.
- Starting method of various motors shall be DOL / Star-Delta
5.3.2. Induction Motors
53
a) Motors shall be capable of giving rated output without reduction in the expected
life span when operated continuously under following conditions.
1. Variation of supply voltage from the rated voltage ± 10 %

2. Variation in supply frequency from the rated frequency ± 5 %
3. Combined Voltage and frequency variation ± 10 %
b) Motors shall be suitable for the method of starting as specified.
c) All the motors shall be of „energy efficient‟ (EFF1 range) type and shall meet the
following requirements:
i) Highest among the commercially available makes & range
ii) Flat efficiency curve between 60% to 100% load
iii) Efficiency shall be guaranteed without any negative tolerance and tested.
d) Motor shall be capable of withstanding locked rotor current for at least 5 seconds
longer than the starting time under rated load conditions.
E) Starting current shall be less than or equal to 600 % of the rated current and the
motors shall be designed for direct on line / reduced voltage starting.
f) Continuous duty motors shall be capable of three equally spread starts per hour
under normal condition or two starts in quick succession from cold or one hot start,
under rated load conditions.
g) The insulation shall be Vacuum and pressure impregnated, shall be given tropical
and fungicidal treatment. These motors shall be sized to operate satisfactorily under
the lowest speed conditions.
h) All bearing to be of lubricated anti-friction type. No forced lubrication acceptable.
NDE bearings of motors of rating 120kW and above shall be insulated for shaft
currents.
i) Terminal box shall be weatherproof construction suitable for outdoor application. It
shall be suitable for top and bottom entry of cables. Terminal box shall be suitable for
termination of XLPE Copper cables. Further, it shall be capable of being turned
through 360° in steps of 90°.
j) External parts shall be finished and painted to produce neat and durable to prevent
rusting and corrosion.
K) The Supplier shall conduct all the routine and type tests as per IS or other
equivalent international standards.
54
5.3.3. Low Voltage (Lv) Panels

Maximum current rating of LV Switchgear shall be limited to 2000 Amps. MCCs
shall be compatible for DCS.
5.3.4. Sheet metal work
The switchgear frame shall be fabricated using Cold Rolled Sheet Steel or Cold
Rolled Cold Annealed of suitable thickness.
5.3.5. Painting
Painting shall be of Synthetic Enamel / Powder coated. For painting seven tanks
method shall be followed. Shade shall be 631 of IS 5. (Light grey & Bright white as
exterior and interior respectively)
5.3.6. Constructional Features

IP-5X construction shall be provided with power connections to the equipment
mounted on withdraw able mounting plate of the bolted type. All identical equipment
and corresponding parts including chassis of draw-out modules of the same size shall
be fully interchangeable.
5.3.7. Low Voltage (Lv) Cables
This specification covers requirement of design, manufacturing, supply and delivery
of low voltage grade cables and accessories like termination etc.
5.3.8. Construction
The cables shall be of XLPE Copper conductor with maximum conductor temperature
of 90 deg. C. For selection of cable, 20 % deration factor shall be considered. For
Three and Half core cables, the current carrying capacity of the neutral conductor
shall be 50% of that of the main phase conductors.
5.3.9. Earthling Equipment

This specification covers the requirement of Earthling of all equipment in the ETP
including Motors, Distribution Boards, Push Buttons and MCC etc. Double Earthling
for motors shall be provided with flexible copper wire and suitable sockets.
Maximum Fault level: 50 kA at 400 V.
Duration of fault: For 400V 1s.
Earth conductor: 2 Nos. separate
50 x 10 mm G I strip,
25 x 10 mm G I strip
55
2.64 sq. mm Bare Copper wire
5.4. Instrumentation
5.4.1. Signals
Electronic range of instruments shall be standardized on 4 to 20 mA signals. The
pneumatic range shall utilize signals of 0.2 to 1 kg/cm2 (g).
5.4.2. General Construction and Supply
All automatic controls, for Fire Protection System shall be provided with electronic
instruments. Only the actuators shall be with pneumatic operation. The
instrumentation shall be suitable for full automatic operation of Fire Protection
System and shall be suitable for hooking – up to a centralized control system.
The centralized control system shall be DCS type, supplied by Employer. All valves
and dampers under automatic and remote control shall be motorized. Standby units
shall have automatic cut in/cut off.
In addition to automatic and remote controls all indicating, integrating, recording instruments,
mounted on a panel for complete Fire Protection System are required. Remote control
instruments and indicating instruments on Fire Protection System floor shall also be
required.
Unless otherwise specified, all indicating and recording instruments shall be flush mounting
pattern with dust and moisture proof covers. Scales shall be of such material that no de-
colorization or peeling takes place with age under humid tropical conditions. The movements
of all electrically operated instruments shall be of the dead beat type and provided wherever
necessary with an accessible zero adjustment.
Appropriate normal places and other operating points shall be marked on the scale face. All
electrical instruments and meters shall comply with British or other equivalent Standards and
unless otherwise specified shall be of industrial grade accuracy. Meters shall be calibrated to
the appropriate grade in British or other equivalent Standards with due allowance being made
for the errors in the associated instrument transformers. Calibration of all instruments shall be
in the units of measurement specified in these documents.
Temperature measurement for temperatures above 150 0C shall be of the thermocouple type
and below 150 0C of resistance type. Pressure gauges shall comply with requirements of
British or equivalent Standards. Stop Cocks shall be fitted adjacent to each pressure gauge
56
and isolating valves included where pressure gauge piping is connected with the main system.
On-plant instruments and gauges are to be locally mounted and fitted in robust cases.
5.5. PAINTING
The equipment shall `be painted before dispatch to site. Painting specifications are furnished
hereunder. To facilitate correct re-assembly at site, colour identification shall be applied to
each plant piece and its associated equipment of the Plant and parts, within a series or train of
similar pieces.
5.5.1 Preparation of Surfaces
Prior to treatment, the metal surface shall be cleaned of dirt and grease, layer of rust, weld
spatter etc. These shall be removed by pickling, power tool chipping, descaling, sanding, wire
brushing or grinding. For wire brush cleaning, the wire brush shall be applied carefully over
the surface in vertical and horizontal direction. For motor driven cleaning; brush, tube cleaner
and disk sander shall be used. The work shall be done in such a way that the brush is applied
over two times on each portion of the object to be treated. Either feather type or gear type
cutter shall be attached to the tube cleaner. Application of the cutter shall be done carefully in
the longitudinal direction except for unavoidable cases.
5.5.2 Recommended types of paints

Painting for Machinery, Equipment of the Plant, and Piping shall be applied as follows
a) Primary coat - Red Oxide Paint
b) Under Coat - Pthalic Anhydride Paint
c) Finish Coat - Pthalic Anhydride Paint
Corrosion protection (wherever required) - Pitch based resinous

Preparation of Paints
Dilution of paints shall be done in accordance with the paint manufacturer's
instructions utilizing the recommended thinners.
a) Use of the paint thinner shall be limited to paint 1 : thinner about 10.
b) No other solution other than the thinner shall be used.
57
c) The prepared paints and the solvents shall be of the same manufacturer.
Method of Painting
Painting shall be done by brush painting or by airless spray. Painting shall be done carefully
by well experienced operators who know the properties of paints sufficiently to obtain the
best results. Paint should be applied:
a) The painting shall be carried out after successful completion of hydraulic and leakage tests
wherever applicable.
b) Immediately after cleaning the metal surface, the first coating paint shall be applied.
For the member of frame to be welded at site, area within 50 mm from the welding lines shall
be kept unpainted before welding. The paints shall be stirred thoroughly and filtered before
use. Utmost care shall be taken not to spoil or damage the painted surface.
- Galvanized steel
- Internal surfaces of vessels, tanks, heat exchangers, etc.
- Machine finished surface where performance shall be adversely affected if painted.
In the case of layered painting, the next painting shall be applied after cleaning the surface of
the previous layer and after a gap of minimum 8 hours drying. The coating thickness of each
layer shall be uniform. Notices, name plates, lettering, gauges, sight glasses and similar items
shall not be painted over and shall be protected during painting by the application of masking
tape and cleaned after painting is over.
The paint work shall be stopped in the following cases:

- When it rains
- When the humidity is over 90 %
- When the ambient temperature is high
Painted Film Thickness

The thickness of finish painted film shall be even. The standard thickness values to be
measured by net micro-thickness gauge shall be as follows:
58
- Red Oxide paint Over 125 (4 Coat Basis)

- Pthalic acid resin paints Over 150 (4 Coat Basis)
Interval of Each Painting
In accordance with the applicable specification and depending on the properties of the paint,
next coating shall be done after the necessary drying period of the paint as instructed below:
a) The optimum time shall be taken for drying, taking into consideration temperature,
humidity, ventilation, coating thickness, air pollution degree and other related factors.
b) No hardening or drying agents shall be used to shorten the drying hours unless proper
measures are taken. The following shall be the standard intervals for painting.
- Red Oxide Paints
- Over 2 days and below 6 days
- Pthalic acid resin
- Over 1 day and below 6 days
Painting Schedule
Final color coding details of individual equipment and pipelines shall be given at the time of
contract finalization, but generally, in accordance with BS-1710 or IS 2379:1990 or other
equivalent standards.
6. TOOL & TACKLES LIST
TOOL & TACKLES LIST FOR EFFLUENT TREATMENT SYSTEM
Item. Item name QTY. Specifications

No
1 Forklift 1 6 Ton
2 Crane 1
3 Ladder 2 3m
4 Ladder/Extendable/ 1 3-6 m
5 Scaffolding 1
6 Wire Ropes, Slings, shackles 1 set
59
7 DC welding plant 2 500 AMP with 30Mtrs. Each welding lead flexible
95mm & holders each
8 welding plant 1 500 AMP with 30Mtrs. Each welding lead flexible
95mm & holders each (rectifire with argon welding
option)
9 Gas cutting set 1
10 Roling / Bending machine 1 3000mm width
11 Chain bloks 1 capacity 20 Ton
12 Chain bloks 1 Capacity 10 Ton
13 Chain bloks 1 Capacity 5 Ton
14 Chain bloks 1 capacity 3 Ton
15 Gas welding set 1
16 Oxygen empity cylinder 2
17 Acetline empity cylinder 2
18 Hammer 4 1/2kg to 5kg Each
19 Adjustable wrench 2 10'' inch
22 Gas cutting Nozzles 2 1/16'' inch
23 Gas cutting Nozzles 2 3/64'' inch
24 Open end spanner 5 set up to 50mm
25 Ring spanner 5 set up to 20mm
26 Grinder 3 9''inch
27 Grinder 3 4 1/2'' inch
28 Expander 1 For tube inner dia 38-45
29 Expander 1 For tube inner dia 96-105mm
30 Ratchet for expander short handle 1
31 Ratchet for expander long handle 1
32 Expander 1 Inner dia. 48-55
60
33 Rough file 5 12''
34 Rough file 5 10''
35 Rough file 5 6''
36 Rough file 5 4''
37 Smooth files 5 12''
38 Smooth files 5 10"
39 Smooth files 6 6"
40 Pipe wrench 5 18"
41 Pipe wrench 5 12"
42 Pipe wrench 5 8"
43 Screw driver set 5 12"
46 Grip plier 5
47 Plier 5
48 Nossle plier 5
49 Measuring tape 10 100m
52 Right angle 2 6"
53 Right angle 2 12"
54 Right angle 2 24"
55 Center punch 4
56 Chisel set 4
57 Tin cutter 2
58 combination set 2
59 Spirit level 5 12"
61
60 Precision level 1 0.002mm, 8" length
61 Central precision level 1
62 Socket spanner set 2 set 6mm to 32mm
63 Oxygen gauges 1
64 Acetline gauges 1
65 Cylinder key 2
66 Tip claener 2
67 steel ruler 2 1m
68 steel ruler 2 300mm
-------------------------------------------//--------------------------------------
62

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FIRE PROTECTION SYSTEM

 Prevent fire damage to assets

 Minimize the effect of a fire in plant facility

 To extinguish the fire in the beginning where it is considered safe to do so

The application of fire cases:

 Reduce the total heat flux to enable an effective fire fighting.

 A source of ignition; and

 A source of oxygen (from air).

 Detect the release of fuel/gas as rapidly as possible: Install fire detector at

 Upon detection of fire:

o Isolate sources of ignition:

o use the applicable fire fighting devices

o Protect adjacent equipment to prevent escalation of the incident:

1.3, CODES AND STANDARDS

1.4, BASIS OF DESIGN

1.5, SYSTEM DESCRIPTION

1. Fire water hydrant, hose box, Fixed monitor

2. High Velocity Water Spray System

3. Raw Water Storage and Pump Station

4. Portable Extinguisher (Dry chemical, CO2, Water/Gas, Sand Bucket)

6. Fire Detection and Alarm Systems

1.6, FIRE FIGHTING AREA

Processing Plant, Storage Tank:

Office and Administration Buildings:

Control room, UPS room, Telecommunication room, Electrical room:

Steam Turbine Building and Boiler House:

Manual Extinguishers, Hydrants and Fixed Monitors will be selected.

1.7, SYSTEM COMPONENT

1.8. TECHNICAL DISCRIPTION OF EQUIPMENT IN FPS

18.1, WATER STORAGE TANK (301)

1.8.2, ELECTRICALLY DRIVEN PUMP (302)

Initiation of Fire Fighting Systems may be manual, automatic or both.

The fire water pump system shall be operated as follows:

 When the fire water ring main pressure is Low-Low

1.8.3, DIESEL ENGINE (DE) DRIVEN PUMP (303)

1.8.4, JOCKEY PUMP (304)

1.8.5, PUMP ROOM (305)

1.8.6, HYDRANT SYSTEM (306)

1.8.7, HYDRANTS AND FIXED MONITORS (307)

1.8.8, HOSE PIPES AND NOZZLES (308)

The contents of each cabinet shall be:

• 2 off 30 meter lengths of 63 mm hose with 63 mm NH couplings

• 2 off 15 meter lengths of 63 mm hose with 63 mm NH couplings

• 1 off adjustable jet/fog nozzles with inlet NH couplings

1.8.9, FIRE EXTINGUISHERS (309)

Class / Category Class of Fire Suitable type of Extinguishers and appliances

The like) Chemical Extinguishers of Soda Acid, Gas /

According to above classification, the categorization of plant and equipment is as under:

General stores (Class B, C)

Sulphur store (Class D)

Cane yard and mill house (Class B and E)

Power house (Class B and E)

Boiler (Class B and E)

Clarification House (Class E)

Boiling House (Class E)

Sugar House (Class E)

Water supply pump house and Effluent treatment plant (Class E)

1.8.9.1, MANUAL FIRE EXTINGUISHERS AT SELECTED LOCATIONS

1.8.9.2, FIRE AT FUEL TANK

1.8.9.3, FIRE AT PROCESSING PLANT AND POWER GENERATION

1.8.9.4, FIRE AT BUILDING

1.8.9.5, FIRE AT STORAGE AREAS