PROJECT : 2x800MW YERMARUS SUPERCRITICAL TPP

OWNER : RAICHUR POWER CORPORATION LIMITED

CUSTOMER : BHARAT HEAVY ELECTRICALS LTD
CONTRACTOR : GENERAL MECHANICAL WORKS PRIVATE LIMITED
REV: 1

S.No BHEL/RPCL/STEAG Comments GMW Reply

Dated 09/01/14 Dated 17/01/14
Write up for Foam protection system (PE-V0-362-522-A092)
Deluge valve for semi fixed foam shall be included Note. However, please note that the additional deluge valve is not required for 
1
the same. As the IBFP‐01 is connected to the hydrant header which is 
This deluge valve shall be included in drawing no PE‐V0‐ completely mechanically actuated unlike the foam system for the tanks, which 
362‐522‐A016 is acutated by the probe type heat detectors on the tank and the deluge valve. 
2 for
Hence no deluge valve is required from the IBFP‐01. Please accept.

Detailed write up of working IBFP (In line balancing foam  Noted. Since this being a bought‐out item, the catalogue for the same is 
3 preparation) for components shall be furnished attached herewith for your reference. Also separate datasheet for the same 
shall be submitted for approval. Please accept.

Page 1 of 1


GENERAL MECHANICAL WORKS PVT LTD

WRITEUP OF FOAM SYSTEM

PROJECT
FIRE DETECTION AND PROTECTION SYSTEM FOR YERMARUS SUPER CRITICAL TPP (2x800MW)
RAICHUR.

Document No : - PE-V0-362-522-A092 REV - 01

CONTRACTOR GMW PVT LTD VADODARA GUJARAT
TITLE WRITEUP OF FOAM SYSTEM
PROJECT FIRE DETECTION AND PROTECTION SYSTEM FOR YERMARUS STPP (2x800MW) RAICHUR
 

CONTENTS

1. General
2. System Description
3. Design Criteria
4. Operation Logic

Client : BHARAT HEAVY ELECTRICALS LTD Rev-A Sheet No.

BHEL Doc. No. PE-VO-362-522-A092 03.07.13 Page 2 of 8
 
CONTRACTOR GMW PVT LTD VADODARA GUJARAT
TITLE WRITEUP OF FOAM SYSTEM
PROJECT FIRE DETECTION AND PROTECTION SYSTEM FOR YERMARUS STPP (2x800MW) RAICHUR
 
1. General

This document contains the salient features of Fixed Foam system proposed to be provided
for protection of following storage vessels in the plant:

a). HFO STORAGE TANKS- 2 NOS, 3004m capacity, each Dia.16m & Ht.17.0m.
b). LDO STORAGE TANK - 2 NOS, 560m3 capacity, each Dia. 9m & Ht. 10.5m.

2. System Description

2.1. The foam system consists of foam pumps (one motor driven and one engine driven), Inline balance
foam proportioners, foam makers, foam discharge outlets, deluge valves, foam tanks, foam
concentrate isolation valves, interconnection piping and instrumentation.

2.2. A semi-fixed system consisting of separate foam solution ring main around the protected tanks
with foam hydrant valves, Water monitor at regular intervals is also provided for protection
against spill fires.

2.3. The operation of fixed foam system is made automatic with the aid of Probe Type Heat Detector
provided in the HFO and LDO tanks.

2.4. Water for the foam system is tapped from the hydrant system. Automatic deluge valves also with
manual control are provided to control flow of water to foam system.

2.5. The foam concentrate used is 100% AFFF type and is stored in 2x100% capacity foam
concentrate tanks. It is discharged to the ratio controller by means of 2x100% capacity foam
pumps through Inline Balancing Foam Proportioner(IBFP).

2.6. Foam concentrate storage tanks are provided with discharge pipe manifolds, individual isolation.

2.7. Gate valve are provided supply lines to foam proportioner to allow the foam concentrate to flow
to foam proportioners as soon as water flows through the ratio controller.

2.8. In order to prevent entry of water in to foam supply lines, non-return valves are provided in these
Lines.

2.9. Strainers are provided in water inlet of deluge valves.

2.10.Manual operation facility is provided to operate foam pump locally through the local push button
Station directly connected to MCC.

2.11.Following equipments are provided in Foam Pump house:

Client : BHARAT HEAVY ELECTRICALS LTD Rev-A Sheet No.

BHEL Doc. No. PE-VO-362-522-A092 03.07.13 Page 3 of 8
 
CONTRACTOR GMW PVT LTD VADODARA GUJARAT
TITLE WRITEUP OF FOAM SYSTEM
PROJECT FIRE DETECTION AND PROTECTION SYSTEM FOR YERMARUS STPP (2x800MW) RAICHUR
 
TABLE-1
Parameters of Foam Equipments

Equipment No. Name of Equipment Nos Details

FP-01 Main Foam Pump 01 Gear Pump, Capacity: 4 m3/hr.
Head : 120 mwc, Drive : Electric Motor
FP-02 Standby Foam 01 Gear Pump, Capacity: 6 m3/hr
Head : 120 mwc, Drive : Diesel Engine
IBFP-01 Inline Balance Foam 01 Balanced pressure type
Proportioner capacity: 1800 lpm, Size: 80 NB
IBFP-02, IBFP-03. Inline Balance Foam 02 Balanced pressure type
Proportioner Capacity: 430 lpm, Size: 80 NB
IBFP-04,IBFP-05 Inline Balance Foam 01 Balanced pressure type
Proportioner Capacity: 1360 lpm, Size: 80 NB
IBFP-06 Inline balance Foam 01 Balanced pressure type
proportioner(standby) Capacity: 1360 lpm, Size: 80 NB
FT-01, FT-02 Foam Tanks 02 Horizontal with flat ends
Capacity: 4000 ltrs
DV185,186,187,188,189 Deluge valve 05 Size: 80 NB

3. Design Criteria

3.1. The complete foam system is designed as per NFPA-11 as follows:

3.1.1. The system is designed considering 3% concentration of AFFF type foam concentrate.

3.1.2. The foam application rate considered is 6.1 lpm per square meter area of oil surface for
fixed roof type tank.

3.1.3. The minimum effective capacity of foam concentrate tank is decided considering simultaneous
operation of foam system for one number HFO tank and LDO tank with supplementary hose
stream for a period of one hour.

3.1.4. Foam hydrants are provided at every 45 M around the HFO/LDO tank farm.

3.1.5. A design Margin of 10% is considered over the calculated foam concentrate capacity, tank
capacity and foam pump capacity.

3.2. The sizing of various equipments of foam system is carried out as per following criteria:

Client : BHARAT HEAVY ELECTRICALS LTD Rev-A Sheet No.

BHEL Doc. No. PE-VO-362-522-A092 03.07.13 Page 4 of 8
 
CONTRACTOR GMW PVT LTD VADODARA GUJARAT
TITLE WRITEUP OF FOAM SYSTEM
PROJECT FIRE DETECTION AND PROTECTION SYSTEM FOR YERMARUS STPP (2x800MW) RAICHUR
 
3.2.1. Capacity of Foam Makers and foam proportioner for HFO tanks.

Diameter of HFO Tank = 16m

Oil surface area
Foam solution application rate
Rate of flow of foam solution
Rate of foam solution including
10%margine
No. of foam makers provided
Therefore, required capacity of
One foam maker
Pressure at inlet of foam maker is
Considered as 3.5 kg/cm2
K-factor of foam maker
= 3.14x162 /4 = 202.06 m2
= 6.1 LPM/m2
= 202.06 x 6.1 = 1235LPM
= 1235x1.1=1360LPM
=1
= 1360 LPM
= 1360 /3.5^0.5 = 727

Based on the above, foam maker of 100NB size (HD make) is selected.

Capacity of foam proportioner = 1360LPM

Foam proportioner of 80 NB size (HD make) is selected.

3.2.2. Capacity of Foam Makers and foam proportioner for LDO tanks.
Diameter of LDO Tank = 9m
Oil surface area = 3.14x92/4 = 64 m2
Foam solution application rate = 6.1 LPM/m2
Rate of flow of foam solution = 64x6.1 = 390 LPM
Rate of foam solution including = 390x1.1=430LPM
10%margine
No. Of foam makers provided = 1
Therefore, required capacity of
One foam maker = 430LPM
Pressure at inlet of foam maker is
Considered as3.5kg/c2
K-factor of foam maker = 430/3.5^0.5 = 229.84

Based on the above, foam maker of 80 NB size (HD make) is selected.

Capacity of foam proportioner = 430 LPM

(One Foam proportioner is connected to two foam makers)

Foam proportioner of 80NB size (HD make) is selected

Client : BHARAT HEAVY ELECTRICALS LTD Rev-A Sheet No.

BHEL Doc. No. PE-VO-362-522-A092 03.07.13 Page 5 of 8
 
CONTRACTOR GMW PVT LTD VADODARA GUJARAT
TITLE WRITEUP OF FOAM SYSTEM
PROJECT FIRE DETECTION AND PROTECTION SYSTEM FOR YERMARUS STPP (2x800MW) RAICHUR
 
3.2.3. Capacity of Foam Maker and foam proportioner for Foam Hydrants - 02 Nos.

Foam Solution for one hydrant = 900 lpm

Simultaneous operation of 02 Foam hydrants = 2 X 900 = 1800 lpm.
Therefore, required capacity of one foam
Proportioner = 1800 lpm

Foam proportioner of 80NB size (HD make) is selected.

3.2.4. Capacity and head of Foam pump

3.2.4.1. Capacity of Foam Pump

Capacity of foam pump is decided considering foam concentrate requirement for
Simultaneous protection of any of the HFO tank and LDO tank
Foam solution requirement of HFO
Tank including 10% margin
(See calculation above) = 1360LPM
Foam concentration = 3%
Foam concentrate requirement for
HFO tank = 1360x0.03 = 40.8LPM
Foam solution requirement of LDO
Tank including 10% margin
(See calculation above) = 430 LPM
Foam concentration = 3%
Foam concentrate requirement for
LDO tank = 430x0.03 = 12.9LPM

Supplementary Hose stream required as per

NFPA-11 189LPM CL.NO.5.9.2.2 for 2 nos = 378LPM
Foam concentration = 3%
Foam concentrate requirement for
Supplementary hose = 378x0.03 = 11.34LPM
Total flow rate of foam concentrate = 40.8 + 12.9+11.34 = 65.04LPM
= 3.902 m3/hr

Selected capacity of foam pump is 4 m3/hr.

3.2.4.2. Head of Foam Pump

The total discharge head requirement of foam pump is calculated as follows:
Min. pressure at inlet of foam maker = 3.5 kg.cm2
Static head loss between foam pump
and foam maker = 1.7 kg/cm2(approx.)
Friction loss in piping = 2.5 kg/cm2(approx.)
Pressure requirement at foam
proportioner outlet = 3.5+1.7+2.5 = 7.7kg/cm2
Pressure required in excess of
Water pressure. = 2 kg/cm2
Design margin = 10 %
Therefore, discharge head of foam pump = (7.7+2) x1.1 = 10.67 kg/cm2

Selected discharge head of foam pump is 12.0 kg/cm2

Client : BHARAT HEAVY ELECTRICALS LTD Rev-A Sheet No.

BHEL Doc. No. PE-VO-362-522-A092 03.07.13 Page 6 of 8
 
CONTRACTOR GMW PVT LTD VADODARA GUJARAT
TITLE WRITEUP OF FOAM SYSTEM
PROJECT FIRE DETECTION AND PROTECTION SYSTEM FOR YERMARUS STPP (2x800MW) RAICHUR

3.2.4.3. Pumping capacity provided:

i. Motor driven foam = 1x4m3/hr. at rated head of 12kg/cm2

(Working)

ii. Engine driven foam pump = 1x4m3/hr. at rated head of 12kg/cm2

(
Standby)

Capacity of Foam Tank

The capacity of foam concentrate tank is decided considering simultaneous operation of

foam system for one number HFO tank and LDO tank with supplementary hose stream.

Foam solution requirement for

one number HFO tank including 10% margin = 1360 LPM
Foam solution requirement for
one number LDO tank including 10% margin = 430 LPM

Supplementary hose stream required as per

NFPA-11 = 378LPM

Foam concentrate requirement for 60 minutes operation with 3%

Concentration = 2168 x 0.03 x 60
= 3902.4 ltrs.
Total foam Concentrate requirement = 3902.4ltrs.

Selected capacity of Foam Tank is 4000 ltrs.

4. Operation Logic

In the event of fire in any HFO/LDO tank, the Probe type Heat detectors in the tank will
detect the fire and will actuate the Deluge valve of respective tank through the solenoid
valve provided in the respective DV trims. Simultaneously, the Main Foam pump
FP-M-01 also starts automatically through the Fire Alarm panel. Water from
hydrant header starts flowing to the IBFP(Inline Balance Foam Proportioner).IBFP
consists of ratio controller, diaphragm operated pressure balancing valve, water and foam
gauges, and pressure sensing hose of Teflon tube with stainless steel braided cover,
interconnecting trim fittings with various control and flush valves. Foam concentrate from foam tank
reaches the ratio controller of IBFP, The water inlet pressure and foam concentrate pressure at
metering orifice is sensed by a diaphragm valve and it automatically balances the concentrate supply to
provide accurately proportioned water foam solution over a wide range of flow conditions. Ensuring
mixing of foam concentrate with water in the right proportion. The foam water mixture flows to
the foam makers provided in the affected tank, where it is converted into foam and discharged in to
the tank. Once the foam is discharged in to the tank, it spreads on the oil surface forming a blanket and
extinguishes the fire.

In case of Semi fixed foam system, foam water solution flows to the foam ring around the dyke, once
the deluge valve operates. As the foam water solution enters the foam piping, ring. Once the ring main
is filled with the solution, foam hydrants shall be operated manually to extinguish the spill fire in the dyke.

Client : BHARAT HEAVY ELECTRICALS LTD Rev-A Sheet No.

BHEL Doc. No. PE-VO-362-522-A092 03.07.13 Page 7 of 8
CONTRACTOR GMW PVT LTD VADODARA GUJARAT
TITLE WRITEUP OF FOAM SYSTEM
PROJECT FIRE DETECTION AND PROTECTION SYSTEM FOR YERMARUS STPP (2x800MW) RAICHUR
 
Stand by IBFP with DV which is interconnected downstream of all working IBFP .The selection of
standby deluge valve can be achieved through isolation valve provided on the downstream side of and
in between standby and working IBFP.

In case, the main foam pump fails to start, “Foam Pump FP-1 Fails to Start” annunciation will
appear through pressure switch PS-02& the standby foam pump will start automatically. As the pump
starts discharging, Pressure switch PS-03 will operate giving “Foam Pump FP-2Running” annunciation.
When main foam pump starts discharging foam concentrate, pressure switch PS-1 operates giving “Foam
Pump FP- 1 Running” annunciation.

Foam water mixture flows out of ratio controller, the pressure switch provided on downstream side of
ratio controller will operate giving annunciation “Foam system operating”.
The set pressure of various pressure operated instruments is as given in the table
below:
TABLE-2
Set pressure of Pressure Switches
Tag No. Type of Instrument Set Pr. Annunciation
(Kg/cm2)
PS-01 Pressure Switch 11.5 Foam Pump FP- 1(motor driven) Running
PS-02 Pressure Switch 11 Foam Pump FP- 1(motor driven) fails to
start
PS-03 Pressure Switch 11.5 Foam Pump FP-2(diesel engine driven)
Running
PS-04 Pressure Switch 11 Foam Pump FP-2(diesel engine driven)
fails to start
PS-05 Pressure Switch 3.5 Foam system for LDO-01 Tank operated
PS-06 Pressure Switch 3.5 Foam system for LDO-02 Tank operated
PS-07 Pressure Switch 3.5 Foam system for HFO -01 Tank operated
PS-08 Pressure Switch 3.5 Foam system for HFO -02 Tank operated

Client : BHARAT HEAVY ELECTRICALS LTD Rev-A Sheet No.

BHEL Doc. No. PE-VO-362-522-A092 03.07.13 Page 8 of 8