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Electrical safety in the plant

5. Fire protection & Alarm systems

1.0 Introduction
Fire Alarm and Protections systems are important form view point of stopping further
damage. Many cases have happened where fire alarm/smoke detection was in non-working
condition and the damage was enormous.
It is easy to install the system, but it requires hard work and determination to keep these
systems in working condition.
Why Fire Safety is required?
• Fire Safety is an imperative step towards a safer workplace.
• Helps prevent direct and indirect losses – production, time, money etc.
• Benefits to the individual workers and the overall company increases.
Benefits of Fire Safety to individuals
• Prevent losses – disability / death
• Ensure work efficiency
• Avoid stress – physical and mental
Benefits of Fire Safety to organization
• Avoid direct losses – compensations / time
• Keep good business practices intact
• Improve employee morale and safety

2.0 Fire Safety has got two aspects:

(a) Reactive Measures: Fire fighting during actual fire break
(b) Pro-active Measures:

Follow statutory guidelines

Intrinsically safe plant design

Risk segregation and safe distances

Follow SOPs & SMPs

Testing of installed hardware

Train shop floor persons & validate training

No human error

Install fire protection systems

Adequate fire water storage capacity

Fire fighting & first aid training

Portable extinguishers at prominent locations

Mock drills & simulation exercises

IMC/PHC/Hospitals/Ambulance

Mutual Aid Services with neighboring industries

Village awareness

Mass communications

No unauthorized population around plant compound walls

3.0 Management of fire Extinguishment

(a) Cooling: Removal of Heat. Water is the best medium
(b) Starvation: Removal of fuel or combustible material
(c) Smothering:

Reducing percentage of Oxygen

Cutting off supply of oxygen

Blanketing by using foam

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5.0 Elements of Fire –

(a) Heat
Heat is one out of several ways of measuring the energy contained in a material or exerted
by it. Major Sources of Heat are Electrical, Mechanical, Chemical and Nuclear.
Modes of Heat Transfer
• Conduction – Direct thermal energy transfer between materials
• Convection – Heat transfer through movement of gases / particles
• Radiation – Wave transfer of heat to a solid substance
(b) Oxygen
• Oxygen acts as a reactant catalyst during the combustion process / fire
• Large amounts of oxygen induces accelerated combustion process
• Normal atmosphere has 21 % oxygen
• Oxygen levels below 16 % greatly slows down the combustion process
• Reducing oxygen in the region is a key to fighting fire
(c) Heat:
There can be one or more sources from following:
• Hot work (welding, cutting, grinding)
• Open flames
• Mechanical - friction sparks or Impact sparks
• Hot surfaces and equipment
• Frictional heating
• Thermal decomposition- (e.g. in transformer oil)
• Electrical spark from electrical equipment
• Electrostatic discharges
• Smoking

6.0 Where Fire can occur in Power Station?

In Power Station, fires commonly emanate from but not restricted to
• Fuel storage – (Liquid fuel or Coal storage & Handling area)
• Substations
• Transformers
• Machine shops
• Pantries, Office buildings, control rooms
• Storage rooms / areas

7.0 Classification of Fire

All types of fires are not the same. Fires are classified based on their sources
• Class A: (A- Ash) Fires caused by ordinary combustibles come under Class A. Some of
the common causes include wood, paper, plastic or cloth.
• Class B: (B – Boil) Fires caused by flammable liquids come under Class B. Some of the
common causes include gasoline, petroleum oil, grease, paint and other flammable
liquids. Transformer oil falls in this group.
• Class C: Fire caused by Electrical hardware comes in this group. This is also called
Electrical fire. It can be caused by short circuit, overload or earth fault.
• Class D: Fires caused by combustible metals come under Class D. Some of the common
metals include Potassium, Sodium, Aluminum, and Magnesium.
• Class K: Cooking Media - Fires involving combustible vegetable or animal non-saturated
cooking fats in commercial cooking equipment.

8.0 There are various systems installed in the power plant for initiation of alarm (in very
initial stage) and fire fighting. In the substations, switch stations, transformer yard, outdoor
switchyards etc. also, such systems/hardware are installed. It is easy to install any system

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or hardware, but it requires determination and hard work to keep these systems in working
condition. These systems are:
• Fire Alarm system
• Smoke Detection system
• High Pressure water jet system for power transformer of rating 10 MVA and above
• Automatic Nitrogen injection system (on sensing the fire signal from tank) on power
transformers
• Fire Water system for fire fighting
There are portable equipments installed at various locations in the plant. These are:
• Fire extinguishers of various types/sizes
• Fire hoses
• Dry sand buckets
• Medium velocity water spray for cable galleries, cable risers, coal conveyers, crusher
houses, DG set building etc
(For further details refer CEA Regulations- Section-5 (Construction of Electrical Plants &
Line) Rule 12(5)(f)(iii)

9.0 Important points during Planning and operation stages

Substation and switchyard safety need to be kept right from planning stage. Proper
management and allowances in the buildings make it simpler to avoid any major fatalities
resulting from fires of any size. Some of the major factors to be considered in planning for
emergency procedures and evacuation include
Planning
• Safe layout of panels & other equipments in substation
• Storage areas (coal storage, liquid fuel storage)
• Escape routes (Emergency exits) going out from substation operating floor / cable cellar.
• Adequate ventilation in substation to keep the equipments operating at safe
temperatures.
Important points in operating plant:
• Exit through elevators must be strictly avoided during emergency.
• In the cable cellar, materials like transformer oil drums, cotton waste, flammable type
liquids (for cleaning electrical components/parts), scrap wood etc shall not be stored.
• Emergency exits passages shall be always kept clear.
• On both sides of emergency exit doors, no material shall be stored, e.g. storage boxes,
wooden scarp, hangings / decorations, broken fans/grills etc.
• Emergency exits locations shall be marked by arrows & text on the wall at strategic
locations.
For emergency doors
• Must not require the use of a key, tool, special knowledge, or effort
• Must allow re-entry to the interior of the building
• Ample type of releasing device to unlock - Lever, knob, handle etc., must be available
• For door pairs, each leaf provided with its own releasing device and not dependent upon
the other.
• On the emergency doors, ‘Emergency Exit” shall be painted in bold red letters.
• Emergency door shall be never kept closed from outside.

Typical Planning of Building Exits

• Readily accessible at all times.
• Provided with safe and continuous passageways, aisles
• At least two exits by separate ways of travel.
• Exits are remotely located from each other to minimize the possibility that more than
one can be blocked.
• No dead ends on corridors

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10.0 Fire extinguishers
Specified types of fire extinguishers (F.E.) need to be used for electrical fires. F.E. used for
Class A fire (water extinguishers or foam extinguishers) shall never be used for fighting
electrical fires. For fire of Class B and C, Carbon-di-oxide or Dry chemical extinguishers are
used.
Carbon-di-oxide extinguishers remove the oxygen element from the fire tetrahedron to
prevent fire. These are used for fires under Class B, C & E. CO2 F.E. is ineffective against
Class A fires.
• Available in various sizes with 2.5-100 lb. at 150-200 psi (8-30 seconds discharge time).
• Capacity is verified by weight.
• These may be hand held or trolley mounted
• It does not have pressure gauge
• 3-8 ft. maximum effective range.
• Extinguishes by smothering burning materials.
• Effectiveness decreases as temperature of burning material increases.
Dry chemical extinguishers operate by stopping chemical reaction (combustion) of fire. It
removes fire by creating a barrier between the fuel and oxygen or by removing heat. DCP
F.E. can be used for Class A fires also.

Class “A”, “B”, “C” and “E” fires.

2.5-20 lb. dry chemical

Pressurized to 50-200 psi

Discharge time 8-25 seconds.

It uses Mono Ammonium Phosphate or Sodium Bi-carbonate

Has pressure gauge to allow visual capacity check.

5-20 ft. maximum effective range.

Extinguishes by smothering burning materials by nitrogen gas

For metal fire, Sodium, Potassium, Barium Chloride mixture is used

How to use fire extinguisher?

P.A.S.S. Method is a common word for this.
(a) Pull the pin - This will allow you to squeeze the handle in order to discharge the
extinguisher.
(b) Aim at the base of the fire - Aiming at the middle will do no good. The agent will pass
through the flames.
(c) Squeeze the handle - This will release the pressurized extinguishing agent.
(d) Sweep side to side - Cover the entire area that is on fire. Continue until fire is
extinguished. Keep an eye on the area for re-lighting.

11.0 Other Systems

11.1 Smoke / CO Detectors
These are important & first line of defense in fire safety, particularly in unmanned area like
cable cellar, UPS rooms etc. In some areas, CO is formed due to incomplete combustion –
(Carcinogenic). Automatic alarms are provided which are active when amount (of smoke or
gas) exceeds specified limits. There are two types of sensors to detect smoke- (a) Ionization
type and (b) Optical type.
Detectors are installed above/below false ceilings or below false flooring (where control
cables are running). Maintenance involves testing, battery change (if found weak) and
cleaning. Periodic cleaning is very important to avoid false alarm. Regular testing is carried
out by simulation with Aerosol spray.

11.2 High Pressure Water spray system for large power transformer:
IS 3034:1993 (Fire Safety of Industrial Buildings: Electrical Generating & Distribution
Stations- Code of Practice) gives measures to be taken for safety against fire in power
plants. It describes the measures in the areas – Control room, Switchgear Room, Cable

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ways/races, coal/oil storage, coal handling system (including coal mills, coal houses,
bunkers, conveyer belts etc), transformer yards, turbine/generator house, boiler house etc.
It stipulates protection of power transformer of 10 MVA and above.

11.3 Break Glass Fire Alarm System

This type of system is quite old. Fire Alarm Panel is located in the Plant Control Room.
Break Glass Units are installed in the field, at strategic locations. These are connected to the
F.A. Panel in CR. In case of fire, the nearest B.G. Unit glass is broken manually. This will
give alarm (hooter) & indication (of location) on the window of the panel. Repeater panels
may be installed at Central Fire Station etc. In very large plants, information of plant is
displayed simultaneously at Medical center, Fire Water pump House & Security desk. It is
very much essential to test the system regularly. By simulation on BG Alarm unit, testing is
done. Proper documentation and drawings of installation are desirable.

11.4 Linear Heat Sensing Cables (Used for fire alarm system.)
These cables are temperature sensitive and these are used on cable trays in cellar or cable
raceways. These are laid in wave shape on each tray. Linear cables have some advantages
over detectors. These do not require maintenance and are more effective.

11.5 New Materials

(a) FRLS cable – Fire Retardant Low Smoke Cable- are used for critical applications.
(b) HFFR cable – Halogen free fire retardant cables. Though cost is higher, safety factor is
more important, hence many new power plants use these cables.
(c) Fire Stop – As per IE Rules these are to be installed inside the cable duct of building
more than 15 Mt high. On every floor crossing it is to be installed to avoid spread of fire.
(d) Argonite: It is one of the media being utilized off late. It is non-conductive and can be
used for electrical fires. This medium consists of 50% Argon and 50% Nitrogen. Nitrogen
reduces Oxygen concentration substantially to a level tolerated by humans over short
periods. This material is environment friendly.

12.0 Fire water lines & Fire water pumps

Type of fire water lines - above ground or underground plays important role in the reliability
of the system. If lines are laid underground its condition monitoring and repairs is
cumbersome. As compared to this, above ground pipelines are easy to maintain. A case had
happened in one power plant that, in case of fire, water could not reach up to power plant,
because the UG lines were corroded and there were lot of leakages.
Fie water pumps are of two types - motor driven and diesel engine driven. Pump may be
auto started by pressure switch signal. For both types of pump, regular check is very
important.

21.0 Case Studies

(a) Fire in the Hydro Power Station

Kadamparai Hydro Power Station is located in Tamil Nadu state. It has 4 # 100 MW
Reversible turbines using 380 Mt water head between two reservoirs (upstream &
downstream). Main equipments are water turbines, generators, cables, twin shaft inclined
penstock, transformers etc. Caverns houses transformers, cables etc. Cables tunnels carry
cable trays. Access to tunnel & tail race tunnels are under ground. During night hours, water
was pumped upstream, by reversing the rotation of turbines. Hydro power station was
connected with TNEB grid by 230 KV lines.
On 19th October 1990, fire started in transformer cavern for unit 1 & 2. Fire ravaged entire
transformer cavern, cable tunnel /shaft and adjoining area for two full days. Fire had spread
rapidly and extensively, due to huge volume of transformer oil. Fire had started from heavy

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sparking at the pot head of one transformer. Fire Detection System was installed had not
worked.
Damage & Effects:
Six power transformers of unit 1 & 2 were totally damaged. Minor damage was there to
cavern roof & sides. Power and control cables got totally burnt. Minor damage to
Generating units & crane Concrete structure of cavern got damaged Significant damage to
equipments & cables in the Control Room.
Plant generation was affected for six years

(b) Fire in cinema theatre

In New Delhi, on 13th June 1997, there was a fire in ‘Upahaar’ cinema, when ‘Border’ was
being screened. There was stampede; 59 persons died. In April ’03, Delhi High Court
ordered to pay the compensation of Rs. 170 million, to heirs of victims. The reason of fire
was the transformer in the cellar. Transformer oil was heavily leaking and it caught fire, due
to high temperature.
No maintenance was done on the transformer, for many years. Smoke Detection System
was not provided in the (unmanned) transformer Room.
57 persons died on the spot. Two died in the hospital The court ordered to pay Rs. 170
million compensation as under:
• 55% to be paid by theater owners
• 15% to be paid by DMC
• 15% to be paid by DVB
• 15% to be paid by Theater Licensing Authority Compensation for persons died in the
incident
Amount to individual was as under:
• Rs 15 lakh each for persons below 20 yrs age
• Rs 18 lakh each for persons above 20 yrs age

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