Critical Maintenance

Problem encountered
and its Solution
Group - 3
Critical Equipment of LPG BPs..
Fire engine
 Important part in the whole Fire Fighting System.
 Statutory Mandate to maintain required no. of Fire engine operational for running the
plant
 Fire Pumps design are inline with Water requirement of High Risk Area
 Most of the plants, + 90 % of performance w.r.t rated capacity of Fire engine is required
to cater the Water requirement of High Risk Area
 Improper Preventive maintenance and any major Breakdown maintenance will
considerably affect the performance of Fire Pumps
Issue faced…
 Reverse running of Fire engine
 Due to non-complete closure of NRV in the delivery line of Fire engine(FE1) after
switching off, Reverse running of Fire engine occurred
 Since another Fire engine(FE2) was running, PMCC Operator could not be able to notice
& identify the reverse running of Fire engine.
 This resulted in continuous running of Fire engine(FE1) in reverse direction more than
10 minutes resulted in seizure of engine
 Major overhauling needed to be carried out for rectifying the issue and FE1 was down for
more than 3 months
 PMCC Operator could have prevented this major breakdown by closing the delivery line
valve if the reverse running of FE1 noticed in the earlier stage itself
Solution S1

S2
 A sensor is installed nearby the Flywheel of Fire engine to
detect the rotation of Flywheel
 In case of reverse running, immediately audio-visual
alarm will be triggered for the particular fire engine
within 5 secs
 The alarm can be acknowledged by PMCC operator and
he can take early measures to stop reverse running of fire
engine by closing the delivery valve
 This will prevent breakdown of Fire engines which is a
major safety concern
 Defined SOP to be formed and displayed in Bilingual for proper
sequence of operation to be carried out by PMCC Operator
incase of alarm
Reverse running alarm functionality check to be done each month
along with other alarms checking by changing the polarity of
sensors and running the engine
Instead of white paint in the Flywheel, reflecting type tape to be
Improvements pasted for better accuracy

Audio/Visual Indication to be integrated to existing Fire Pump

panel

If the idea is accepted by HO, the reverse running indication can

be incorporated in tender terms during procurement of new FEs
Thank you..