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FIRE PROTECTION ENGINEERING TOPIC 27.

10

PROCEDURES FOR INSPECTION, TESTING, AND MAINTENANCE OF CARBON DIOXIDE (CO2) EXTINGUISHING SYSTEMS

Original Document: August 1, 2008


Minor Revisions: June 22, 2009

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Fire Protection Engineering Topic No. 27.10 Procedures for Inspection, Testing, and Maintenance of Carbon Dioxide (CO2) Extinguishing Systems TABLE OF CONTENTS I. II. III. SCOPE..................................................................................................................... 1 DEFINITIONS........................................................................................................ 2 WEEKLY INSPECTION PROCEDURES (LOW PRESSURE CO2) ............. 3 A. B. C. IV. Pre-Inspection Procedures ......................................................................... 3 Inspection Procedures................................................................................. 3 Post-Inspection Procedures ........................................................................ 4

MONTHLY INSPECTION PROCEDURES ...................................................... 5 A. B. C. Pre-Inspection Procedures ......................................................................... 5 Inspection and Test Procedures ................................................................. 5 Post-Inspection Procedures ........................................................................ 7

V.

SEMI-ANNUAL (6-MONTH) PROCEDURES .................................................. 8 A. B. C. Pre-Inspection Procedures ......................................................................... 8 Test Procedures ........................................................................................... 8 Post-Test Procedures................................................................................... 8 Pre-Inspection Procedures ......................................................................... 9 Test Procedures ......................................................................................... 10 Maintenance Procedures .......................................................................... 10 Post-Inspection Procedures ...................................................................... 11

VI.

ANNUAL PROCEDURES .................................................................................... 9 A. B. C. D.

VII.

5 YEAR PROCEDURES ..................................................................................... 12

VIII. 10 YEAR PROCEDURES ................................................................................... 12

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Fire Protection Engineering Topic No. 27.10 Procedures for Inspection, Testing, and Maintenance of Carbon Dioxide (CO2) Extinguishing Systems I. SCOPE This Topic and any associated topics are owned by Ford Corporate Fire Protection Engineering, Corporate Security and Fire. These requirements apply to all Company owned and leased facilities including subsidiaries of Ford Motor Company. Where Local, State, Federal, or National codes are more stringent than these standards, or other Company standards referenced here; the more stringent requirements shall be followed. This Topic provides procedures for conducting inspections, testing, and maintenance of carbon dioxide (CO2) extinguishing systems. The purposes for these procedures are to assure that the systems will be fully operable in case of fire and to reduce the probability of a discharge when there is no fire. This Topic supplements the requirements of Fire Protection Engineering Bulletin 27, Inspection, Testing, and Maintenance Requirements for Fire Protection Systems and Equipment and NFPA 12, Carbon Dioxide Extinguishing Systems. Additional Bulletins, Standards, and codes for reference are: Bulletin No. 9, Carbon Dioxide (CO2) Extinguishing Systems. Bulletin No. 2, Fire Equipment Impairment Procedures. Bulletin No. 20, Bulletin Deviation Variance Protocol. Topic 27.14, Procedures for Inspection, Testing, and Maintenance of Proprietary Fire Alarm Panels and Circuits. NFPA 72, National Fire Alarm Code. Ford Motor Company, Confined Space Entry Procedures, http://www.hps.ford.com/confined_space_entry.htm Ford Motor Company, Fall Protection, http://www.hps.ford.com/safety/saf108.htm Ford Motor Company Power Lockout Procedures - Energy Control and Power Lockout (ECPL), http://www.hps.ford.com/ecpl.htm.

Ford Motor Company P. Armout (parmour1) Corporate Security and Fire June 22, 2009

Page 1 of 13 SFD File No.: Topic 27.10 Record Retention Code: S + 5, O

Transient Record Doc Name: Topic 27.10 (2009) Security: Proprietary

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Fire Protection Engineering Topic No. 27.10 Procedures for Inspection, Testing, and Maintenance of Carbon Dioxide (CO2) Extinguishing Systems Written approval is required from Corporate Fire Protection Engineering or the National Fire Protection Engineer for deviations from the following requirements. II. DEFINITIONS Auxiliary Equipment Equipment used in conjunction with a CO2 extinguishing system. Examples are interlocks to shut down the power and/or fuel supply to equipment or to initiate signaling devices. Carbon Dioxide (CO2) Extinguishing System A means of applying CO2 that can be automatically and manually activated to discharge CO2 through a distribution system onto or into the protected hazard. The system includes auxiliary equipment. High Pressure System Steel cylinders, usually 23, 34, or 45 kg (50, 75, or 100 lb) liquid capacity, are used to store the CO2 at high-pressure and room temperature. The CO2 in the cylinders is stored at between 55-62 bars (800-900 psi). The cylinders are arranged in banks and individually connected to a common discharge manifold. A piping system carries the CO2 to discharge nozzles. A connected reserve bank of cylinders may be provided. The reserve bank permits a secondary automatic or manual discharge if additional CO2 gas is needed to extinguish the fire. Local Application A system consisting of a supply of carbon dioxide arranged to discharge directly on the burning material. Local application may reduce the oxygen in the atmosphere within a room or enclosure to the point where life cannot be sustained. Low Pressure System In a low-pressure system, liquid CO2 is stored in an insulated pressure vessel (storage unit or tank) that is refrigerated. The CO2 exerts an internal pressure of about 20.7 bars (300 psi). Two or more hazards are often protected by a single low pressure storage unit. The liquid CO2 is delivered through pipes to discharge nozzles. Automatic systems are equipped with a timer control that permits a discharge for a period calculated to extinguish the fire and then shuts off the discharge of CO2. Pressure relief valves are provided on the CO2 storage vessel to

Ford Motor Company P. Armour (parmour1) Corporate Security and Fire June 22, 2009

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Fire Protection Engineering Topic No. 27.10 Procedures for Inspection, Testing, and Maintenance of Carbon Dioxide (CO2) Extinguishing Systems release excess pressure if the refrigeration fails and the temperature and pressure begin to rise. Total Flooding A system consisting of a supply of carbon dioxide arranged to discharge into, and fill to the proper concentration, an enclosed space or enclosure around the hazard. Total flooding reduces the oxygen in the atmosphere within a room or enclosure to the point where combustion and life cannot be sustained. See Bulletin 9 and Bulletin 27 for additional definitions. III. WEEKLY INSPECTION PROCEDURES (LOW PRESSURE CO2) This procedure only applies to low pressure CO2 tanks. A. Pre-Inspection Procedures 1. Obtain the inspection checklist or bar code inspection program for the system(s) to be inspected. This document will be used to record all problems observed. Obtain the keys to any locked area where low pressure CO2 tanks are located. Obtain needed equipment or tools. These may include a flashlight to use in unlit areas, a wrench or screwdriver to open inspection and maintenance access openings, a ladder or other equipment to access equipment located at elevated levels, and required PPE. Notify the operator of the facilitys main fire alarm control panel (plant security, plant fire department, or outside fire alarm monitoring company) prior to entering locked areas.

2. 3.

4.

B.

Inspection Procedures Record problems or damage on the plant inspection checklist or bar code inspection program. 1. After arriving at the storage unit to be inspected, verify that it is clearly and properly labeled. The label should include an identification number on each unit. Verify that the system being inspected matches the location specified on the plant inspection checklist or bar code inspection program.
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Ford Motor Company P. Armour (parmour1) Corporate Security and Fire June 22, 2009

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Fire Protection Engineering Topic No. 27.10 Procedures for Inspection, Testing, and Maintenance of Carbon Dioxide (CO2) Extinguishing Systems 2. Inspect the liquid level gauge on the CO2 tank. If it is more than 10% below normal level, it shall be refilled. Report the condition to the appropriate supervisor to submit a maintenance request to correct the problem. Inspect the system control panel if provided to verify that it is connected and showing the normal and ready condition. Report any fire alarm or trouble signals.

3.

C.

Post-Inspection Procedures When the inspection is complete, perform the following: 1. Notify the operator of the facilitys main fire alarm control panel (plant security, plant fire department, public fire department, or outside fire alarm monitoring company) that the testing has been completed. Return all keys, tools, and equipment to their normal locations. Record the name and organization of the person(s) who performed and/or witnessed the inspection and the date of the inspection. Record all results obtained from the inspections described above. Also record all problems and impairments discovered. Any problems discovered during any inspection shall be immediately reported to the appropriate supervisor. The supervisor shall submit an emergency request to correct the problem if a fire protection system is impaired. Corrective action shall be taken immediately. All problems and follow-up action shall be documented. The Bulletin 27 Inspections - Action Items form may be used. All records shall be kept on site and available for inspection for at least one year.

2. 3.

4.

5. 6.

Ford Motor Company P. Armour (parmour1) Corporate Security and Fire June 22, 2009

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Transient Record Doc Name: Topic 27.10 (2009) Security: Proprietary

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Fire Protection Engineering Topic No. 27.10 Procedures for Inspection, Testing, and Maintenance of Carbon Dioxide (CO2) Extinguishing Systems IV. MONTHLY INSPECTION PROCEDURES A. Pre-Inspection Procedures 1. Obtain the inspection checklist or bar code inspection program for the system(s) to be inspected. This document will be used to record all problems observed. Make necessary notifications and other arrangements to implement required safety procedures such as Ford Motor Company Power Lockout Procedures and/or Confined Space Entry. Obtain the keys to any locked area where extinguishing system agent cylinders or other components are located. Obtain needed equipment or tools. These may include a flashlight to use in unlit areas, a wrench or screwdriver to open inspection and maintenance access openings, a ladder or other equipment to access equipment located at elevated levels, and required PPE. Notify the operator of the facilitys main fire alarm control panel (plant security, plant fire department, or outside fire alarm monitoring company) prior to entering locked areas.

2.

3. 4.

5.

B.

Inspection Procedures Record problems or damage on the plant inspection checklist or bar code inspection program. 1. After arriving at the extinguishing system to be inspected or tested, verify that it is clearly and properly labeled. Verify that the system being inspected matches the location specified on the plant inspection checklist or bar code inspection program. Inspect the manual actuation station(s) to verify the following: a. b. c. The station is accessible. The station is free of observable damage. The safety pin and seal are intact.

2.

Ford Motor Company P. Armour (parmour1) Corporate Security and Fire June 22, 2009

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Transient Record Doc Name: Topic 27.10 (2009) Security: Proprietary

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Fire Protection Engineering Topic No. 27.10 Procedures for Inspection, Testing, and Maintenance of Carbon Dioxide (CO2) Extinguishing Systems d. A service tag documenting the most recent semiannual service by a qualified vendor is present. Verify that less than 6 months have elapsed since the date shown on the tag.

3.

Inspect the high pressure cylinder(s) or low pressure tank containing the extinguishing agent to verify the following: a. b. c. d. e. f. High pressure cylinder(s) are in place. High pressure cylinders are properly secured. No visibly damaged or disconnected piping, cabling, wiring, or other components. The liquid level of the low pressure storage unit is within 10% of normal. For low pressure storage units, verify that the tank shut off valve and the pilot pressure supply valve are open. A service tag documenting the most recent semiannual service by a qualified vendor is present. Verify that less than 6 months have elapsed since the date shown on the tag. It is not necessary to have a tag on the cylinder(s) or tank if a tag is provided at the manual release station.

4.

Inspect the system control panel, if provided, to verify that it is connected and showing the normal and ready condition. Report any fire alarm or trouble signals. If the system is inoperative, follow Bulletin 17 procedures for a Hidden Impairment including restricted operations and fire watch or patrols. Inspect the protected hazard area to verify the following: a. The arrangement of the hazard has not changed. 1) 2) Verify that a local application system covers the entire hazard. Verify that the enclosure protected by a total flooding system has no new penetrations.

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6.

Ford Motor Company P. Armour (parmour1) Corporate Security and Fire June 22, 2009

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Fire Protection Engineering Topic No. 27.10 Procedures for Inspection, Testing, and Maintenance of Carbon Dioxide (CO2) Extinguishing Systems b. c. d. C. Discharge nozzles are connected, properly oriented and free of obstructions and foreign matter. Detectors are in place and free of obstructions and foreign matter. Doors to protected areas are not blocked open.

Post-Inspection Procedures When all inspection is complete, perform the following: 1. Notify the operator of the facilitys main fire alarm control panel (plant security, plant fire department, public fire department, or outside fire alarm monitoring company) that the testing has been completed. Return all keys, tools, and equipment to their normal locations. Record the name and organization of the person(s) who performed and/or witnessed the inspection and the date of the inspection. Record all results obtained from the inspections described above. Also record all problems and impairments discovered. Any problems discovered during any inspection shall be immediately reported to the appropriate supervisor. The supervisor shall submit an emergency request to correct the problem if a fire protection system is impaired. Corrective action shall be taken immediately. If the service tag is more than 6 months old, submit a request for service. All problems and follow-up action shall be documented. The Bulletin 27 Inspections - Action Items form may be used. All records shall be kept on site and available for inspection for at least one year.

2. 3.

4.

5. 6. 7.

Ford Motor Company P. Armour (parmour1) Corporate Security and Fire June 22, 2009

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Transient Record Doc Name: Topic 27.10 (2009) Security: Proprietary

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Fire Protection Engineering Topic No. 27.10 Procedures for Inspection, Testing, and Maintenance of Carbon Dioxide (CO2) Extinguishing Systems V. SEMIANNUAL (EVERY 6 MONTH) PROCEDURES The following procedures shall be performed by a qualified vendor. The procedures shall also be performed after a system discharge or any fire in the protected hazard. A. Pre-Test Procedures 1. Make necessary notifications and other arrangements to implement required safety procedures such as Ford Motor Company Power Lockout and/or Confined Space Entry Procedures. Obtain the keys to any locked area where extinguishing system components are located. The vendor shall provide all needed tools and equipment, including PPE. Notify the operator of the facilitys main fire alarm control panel (plant security, plant fire department, or outside fire alarm monitoring company) prior to beginning work. Weigh all high pressure cylinders except those on self-weighing scales. Any cylinder that shows a loss of net content (normal total weight less the weight of the cylinder) of more than 10% shall be refilled or replaced. C. Post-Test Procedures When all inspecting and testing is complete, perform the following: 1. 2. 3. Restore the system, including auxiliary equipment, to full operating condition. The vendor shall affix a tag or label indicating the date of service and all other required information. Notify the operator of the facilitys main fire alarm control panel (plant security, plant fire department, public fire department, or outside fire alarm monitoring company) that the testing has been completed. Return all keys to their normal locations.
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2. 3. 4.

B.

Test Procedures

4.

Ford Motor Company P. Armour (parmour1) Corporate Security and Fire June 22, 2009

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Fire Protection Engineering Topic No. 27.10 Procedures for Inspection, Testing, and Maintenance of Carbon Dioxide (CO2) Extinguishing Systems 5. The vendor shall record the name and organization of the person(s) who performed and/or witnessed the inspection and the date of the inspection. Record all results obtained from the inspections described above. Also record all problems and impairments discovered. Any problems discovered during any inspection shall be immediately reported to the appropriate supervisor. The supervisor shall submit an emergency request to correct the problem. If the extinguishing system is inoperable, the protected equipment shall not be used except as permitted by Bulletin 17. Corrective action must be taken immediately. All problems and follow-up action shall be documented. The Bulletin 27 Inspections - Action Items form may be used. All records shall be kept on site and available for inspection for at least two years.

6.

7. 8. VI.

ANNUAL PROCEDURES The following procedures shall be performed by a qualified vendor. The procedures shall also be performed after a system discharge or any fire in the protected hazard. A. Pre-Test Procedures 1. Make necessary notifications and other arrangements to implement required safety procedures such as Ford Motor Company Power Lockout and/or Confined Space Entry Procedures. Obtain the keys to any locked area where extinguishing system components are located. The vendor shall provide all needed tools and equipment, including PPE. Notify the operator of the facilitys main fire alarm control panel (plant security, plant fire department, or outside fire alarm monitoring company) prior to beginning work. Test all alarm system initiating devices.
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2. 3. 4.

5.

Ford Motor Company P. Armour (parmour1) Corporate Security and Fire June 22, 2009

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Fire Protection Engineering Topic No. 27.10 Procedures for Inspection, Testing, and Maintenance of Carbon Dioxide (CO2) Extinguishing Systems B. Test Procedures Perform all procedures as required by NFPA 12 including appendices. 1. Verify that all CO2 containers are properly filled and that any CO2 cylinder is current on the hydrostatic testing requirement. Any containers whose contents are more than 10% below normal capacity shall be refilled or replaced. Verify that the required safety upgrades per NFPA 122005 have been installed. Test the operation of the extinguishing system including the following: a. Operation of the detection system and releasing devices, including the manual release station(s). Test all detectors and releasing stations as required by NFPA 72. Operation of all interlocks such as power, equipment, or fuel shutdowns and closure of interlocked doors and dampers. Only discharge CO2 to verify the functionality of such items as door closers, and dampers. Limit CO2 discharge to only the amount that is necessary to operate these devices. Verify proper operation of the time delay. Verify all associated equipment interlocks, such as sumps, oil supply pumps, and ventilation. Test battery, power supply, and control panel functions per NFPA 72 and Topic 27.14. Check all circuit and circuit fault functions per NFPA 72 and Topic 27.14. Check the function of all selector (directional) valves.

2.

b. c.

e. f. f. g. h. C. 1.

Maintenance Procedures All defective components or parts revealed by inspection and testing of the system shall be repaired or replaced in accordance with the manufacturers instructions. Fusible link releasing devices shall be replaced annually.

2.

Ford Motor Company P. Armour (parmour1) Corporate Security and Fire June 22, 2009

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Transient Record Doc Name: Topic 27.10 (2009) Security: Proprietary

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Fire Protection Engineering Topic No. 27.10 Procedures for Inspection, Testing, and Maintenance of Carbon Dioxide (CO2) Extinguishing Systems D. Post-Inspection Procedures When all inspecting and testing is complete, perform the following: 1. 2. 3. Restore the system, including auxiliary equipment, to full operating condition. The vendor shall affix a tag or label indicating the date of service and all other required information. Notify the operator of the facilitys main fire alarm control panel (plant security, plant fire department, public fire department, or outside fire alarm monitoring company) that the testing has been completed. Return all keys to their normal locations. The vendor shall record the name and organization of the person(s) who performed and/or witnessed the inspection and the date of the inspection. Record all results obtained from the inspections described above. Also record all problems and impairments discovered. Any problems discovered during any inspection shall be immediately reported to the appropriate supervisor. The supervisor shall submit an emergency request to correct the problem. If the extinguishing system is inoperable, the protected equipment shall not be used except as permitted by Bulletin 2. Corrective action must be taken immediately. All problems and follow-up action shall be documented. The Bulletin 27 Inspections - Action Items form may be used. All records shall be kept on site and available for inspection for at least two years.

4. 5.

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Ford Motor Company P. Armour (parmour1) Corporate Security and Fire June 22, 2009

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Fire Protection Engineering Topic No. 27.10 Procedures for Inspection, Testing, and Maintenance of Carbon Dioxide (CO2) Extinguishing Systems VII. 5 YEAR PROCEDURES The following procedures shall be performed by a qualified vendor. A. Test Hoses (including hoses used as flexible connectors) 1. 2. B. C. Test all hose, including hoses used as flexible connectors, as required by NFPA 12. Mark and destroy all hose assemblies that fail the test.

Weigh all cylinders including those on self-weighing scales. This is needed to verify that the scale is properly calibrated. Cylinders and storage units or tanks that have been in service continuously for 5 years or more shall be inspected as required by NFPA 12, including Annexes. Records of inspections and tests shall be retained until the tests or inspections are repeated or the equipment is replaced or removed.

D.

VIII. 10 YEARS PROCEDURES The following procedures shall be performed by a qualified vendor. A. A thorough inspection of the hazard is required. If there is any concern a puff test of the system may be completed. Contact the Manager of Corporate Fire Protection. If there have been significant changes such as construction, or room layout that may affect concentration levels a full discharge test may be necessary to verify concentration levels. Contact the Manager of Corporate Fire Protection for direction. Records of tests shall be retained until the tests are repeated or the equipment is replaced or removed.

B.

C.

Ford Motor Company P. Armour (parmour1) Corporate Security and Fire June 22, 2009

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