Hand Out Fire Surpress

PRM30400: Certificate III in Asset
Maintenance
UNIT: PRMPFES27A
Install, inspect and maintain a pre-engineered foam fire
suppression system
Sabtu 25 November 202 Hand Out Fire Suppression copy f 1

3 rom Chubb Fire PRMPFES27A
Contents
Theory
Session 1: Installation
Session 2: Testing
Session 3: Maintain & Repair
Practical
Session 4: Design
Session 5: Installation
Session 6: Maintenance

Install a pre-engineered foam fire
suppression system

Session 1 Learning outcomes:
When you have successfully

completed this unit, you will be able:
 Explain the requirements for work permits at a customers’ site.

 Confirm that the installation site is appropriate for the fire risk, customer
requirements, federal regulations, relevant governing bodies and
manufacturers’ specifications.
 Install and commission a foam fire suppression system according to safety
procedures and manufacturers specifications.
 Complete and distribute all necessary documentation.

Content
Topic 1: What is a pre-engineered foam fire suppression
system?
Topic 2: Work permits.
Topic 3: System operation.
Topic 4: Identifying components
Topic 5: Extinguishing Agent - Foam
Topic 6: Cylinder fill ratios
Topic 7: Foam types
Topic 8: System design
Topic 9: Nozzle selection and placement
Topic 10: Installation tips.

What is a pre-engineered foam
fire suppression system?
 A pre-engineered foam fire suppression system is designed
to suppress fires involving ordinary combustible materials
such as wood and paper (Class A) and flammable and
combustible liquids and greases (Class B), on off-road
vehicles, stationary engines and similar heavy machinery.
 Pre-Engineered? - Means that the fundamental design
limitations of the foam fire suppression system have been
determined beforehand so that a competent person can:
Apply the design with confidence, knowing that the system
will perform as predicted.
 At present, there are no nationally recognised protocols for
the Design, Installation or Maintenance of P.E.F.S. All
installations are carried out according to the relevant
manufacturers guidelines!

How does a pre-engineered
foam fire suppression system
work?
 Manufacturers have developed a range of
vehicle foam fire suppression systems that
operate in similar ways. The mode of
operation may vary according to customer
requirements.
 The components vary between
manufactures, but usually operate under the
same fundamental principles.

Types of Installations
Manual System
 Initiated by Operator only.
Manual / Auto System.
 Initiated by Operator or activation device (Non – electrical)
Monitored Manual / Auto System
 As above plus fire alarm (Pressure switch monitoring only)
Monitored Electrical Manual / Auto System
 As above plus electrical activation .
All monitored systems (Fitted with

Fire Alarm Panel) usually have
engine Hand
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shutdown capability.
Out Fire Suppression copy f 8
How does a pre-engineered foam fire
suppression system work?
Fire occurs in protected area.
Detected by operator Detected by auto activation Detected by device.

device. (Electrical) (Pyrotube)
Manual activator used. Fire Alarm activated. Fire Alarm activated.
Operator alerted. Fire system activated.

Fire system activated. (May initiate manual activation)
Fire Alarm activates Operator alerted.

Engine Shutdown initiated the fire system. (May initiate manual activation)
(Where fitted) (E.g. detonator, solenoid)
Engine Shutdown initiated Engine Shutdown initiated

(Where fitted) (Where fitted)

For your own safety, it is important that
you do not undertake any task that you
have not been trained to do. If you are
unsure, always ask your supervisor.

System Operation
 By definition, a foam fire suppression system has two
modes of operation, both of which refer to how the
activation of the cylinder valve is achieved.
1. Rise of Pressure. (ROP)

2. Loss of Pressure. (LOP)

1. Rise of Pressure. (ROP)
A R.O.P system requires a rise of pressure from a remote device to
activate the cylinder valve and discharge the extinguishing agent.
1. Kenaikan pressure dari suatu alat

yang dioperasikan oleh valve cylinder
(ROP)
2. Releases the stored pressure and

extinguishing agent from the cylinder

2. Loss of Pressure. (LOP)
A L.O.P system requires a loss of pressure from a remote device to
activate the cylinder valve and discharge the extinguishing agent.
1. Loss of Pressure from a remote device

operates the cylinder valve
2. Releases the stored pressure and

extinguishing agent from the cylinder

Identifying components.

Types of Pre-Engineered Systems - QSII
Rise of Pressure Loss of Pressure

Assembly Assembly
Rise Of Pressure Cylinder Valve
 Chrome Plated Brass

 Rugged Construction
 Low Maintenance
 Easy to Service

Loss Of Pressure Cylinder Valve
 Stainless Steel
 Differential Pressure Operation
 Rugged Construction
 Low Maintenance
 Easy to Service

Siphon Tubes
Flexible - allows for vertical or horizontal

mounting of cylinders
Brass and Stainless Steel construction with
reinforced nitrile rubber hose

Cylinders
 5 sizes, manufactured in 304 Stainless Steel
 Fitted with Anti-Overfill tubes
 Reinforced neck ring
 Specified by Water Capacity
 C23, C30, C45, C65 & C106 litre cylinders
Cylinder C23 C30 C45 C65 C106

Diameter 216 318 360 360 360
Height 726 512 572 772 1188
H
H
H
H

Vehicle Brackets
M 12 BO LT
W ASHER
RUBBER SPACER
BRACKET
V IB R A T IO N D A M P E R
M A C H IN E R Y
S P R IN G W A S H E R
M 12 NU T
D E T A IL A
 Carbon Steel
 Vibration Dampers available
 Horizontal or Vertical Mounting
 Heavy Duty bracket available

Discharge Components
 Stainless Steel Tube
 Hose & Tube Clamps
 Discharge Nozzle Kits
 Flexible Hose
 RED branded “Fire
Suppression”
 1/4’, 1/2” & 3/4”
 SAE 100R1AT
 fire resistant

Nozzle Assembly’s
 Nozzle Kits can be altered to

suit specific applications.
 Each nozzle kit comes with a
BM17N 60° High Flow
Nozzle. )
 Six standard kits are
available

Actuation Components ROP- Automatic Pyrotube
Actuation
 Operates when temperature exceeds 175oC
 Generates pressure of up to 11 MPa
 Active along its entire length
 Maximum ambient operating
temp. must be less than 100oC
to prevent deterioration
 Must always be installed with a
Pyrotube filter
 Doubles as actuation &
detection
– avoid close proximity to turbo chargers

and exhaust system components

Actuation Components - Electrical Actuation
(Optional)
 Used in conjunction with

electronic thermal or flame
detectors
 12V or 24V options
 Can be used on both LOP and
ROP systems

Actuation Components ROP- Manifolds
 Manifold Block used to

connect ROP & LOP
actuation circuits
 Check Valves required at

junctions on ROP systems

Typical ROP actuation system

Actuation Components LOP- Manual Actuators
 2 types
 Internal
 External
 Internal Model
 interfaces with monitoring/engine
shutdown panel
 External Model
 connection for pressurizing
cylinder and detection system

Actuation Components LOP-
Automatic Actuation
119237 119235 118837 119234 119236
¼" O-RING FACE

SEAL MALE
119226
 Plastic Fire Detection Tubing
 Melts at 160 -180oC
 Maximum operating temperature must
be less than 90oC to prevent
deterioration
 avoid close proximity to turbo
chargers and exhaust system
components
 Installed life of 1 year

Typical LOP actuation system

Electrical components
Fire Alarm Panels
 Standard Panel - alarm only
 Shutdown Panel - alarm and automatic
engine shutdown functions
Pressure Switches
 Weatherproof connections
 N/O or N/C option
Optical Detection
 Detection of fires from light to heavy
hydrocarbon fuels connections
 Responds to a fire in the presence of
modulated blackbody radiation

Typical Dual Optical Detection &
Actuation

Extinguishing Agent - Foam
Pre-engineered foam fire suppression systems are designed
specifically to apply a non-aerated foam solution.
AERATED FOAM SOLUTION IN ACTION

It is the aqueous film and not the foam that produces a continuous
separation between
the fuel, oxygen and flame. The foam protects this film from heat and
replenishes it.
NON-AERATED FOAM SOLUTION APPLICATION

Aerated foam will slow run off vertical surfaces, thus leaving the hazard
exposed
to re-ignition. To over come this, foam is applied in non-aerated droplets
over an
extended period. In this way a film of AFFF solution is maintained on the
surface of the
hazard.

Cylinder Fill Ratios
 A manufacturer may have designed a foam fire suppression system where each cylinder is to
have a maximum fill ratio of 80%. The fill ratio will be determined by the type of foam concentrate
being used. The following table shows the fill ratios for a range of cylinders where a 6% AFFF
foam is to be used.
 The fill ratio’s for the QSII system can be found in the maintenance and design manuals. For
Example:
PART DESCRIPTION TOTA WATE AFFF PRESSURE HEIG

NO. L R 6% HT
CHA CONT CONT MM
RGE ENT ENT
6011/12 CYL ASSY C23 ROP QS2 18 lt. 16.9 lt. 1.1 lt. 1350kPa 960
Foam Types
QSII
PROPERTY PROTEIN FLUORO- AFFF FFFP AR-AFFF
PROTEIN
1. KNOCKDOWN FAIR GOOD EXCELLE GOOD EXCELLE
NT NT
2. HEAT EXCELLE EXCELLE GOOD GOOD GOOD
RESISTANCE NT NT
3. FUEL POOR EXCELLE MODERAT GOOD MODERA
TOLERANCE NT E TE
(HYDROCARBO
NS)
4. VAPOR EXCELLE EXCELLE GOOD GOOD GOOD
SUPPRESSION NT NT
5. ALCOHOL NONE NONE NONE LIMITE EXCELLE
TOLERANCE D NT

System design
In order to install a pre-engineered foam fire suppression
system correctly, you need to be familiar with the
manufacturers design criteria. The following topic will
provide you with information on.
 Fire risk assessments
 Determining potential hazard areas
 Calculating foam quantity
 Nozzle selection and placement

Fire Risk Assessment
 A Risk Assessment must be completed for each system
design
 Why?
 To clearly identify the likely consequences of a fire
 To clearly define the likely sources of fire risk
 To clearly identify what parts of the vehicle we are able
to protect with the Quell Series II System
 Based upon the result of the risk assessment, we must
clearly articulate to the client which parts of the vehicle the
Quell Series II System will protect

Fire Risk Assessment
 A Risk Assessment section is provided in the Quell Series II

Design,Installation & Commissioning Manual and Quell Series II Lotus
Notes Design database
 In undertaking a risk assessment, it is essential that input is obtained

from both the vehicle manufacturer and/or end user to ascertain previous
failure/fire experience on similar machines

Potential Fire Hazards
 Ignition Sources
 Exhaust Manifolds
 Turbo Chargers
 Alternators/Generators
 Starter Motors

Fuel Sources
Fuel & Oil Filters
Fuel Pump
Hydraulic & Fuel Lines
Engine Valley (debris)
Build up of class A combustibles
(forestry/harvesting machinery)

Potential Fuel sources

Potential Ignition sources

Design Database
 Every Risk Assessment & System Design must be recorded

in the Quell Series II Lotus Notes database
 The Quell Series II Lotus Notes database also includes

design software to assist in the design process
 Systems must be designed and installed in accordance with

design guidelines any deviation from these must be approved
in writing by CFA engineering

Design Criteria
 Minimum Foam Application Rate

 4.1 lpm/m2
 based on surface area of hazard
 Minimum Discharge Time

 50 seconds (WA - DOM, check local
requirements)
 Draft ACARP Standard - 90 seconds

Step A: Calculate Hazard Area
Top: Length x Width

Front: Width x Height
Back: Width x Height
Left Side: Length x Height
Right Side: Length x Height
 Area calculation is based on the sides of the smallest imagined box in which
the hazard to be protected would fit (NOT the area based on the walls of the
actual compartment)
 Bottom surface is not normally included unless there is a specific hazard to be

protected there

Calculate Foam Quantity
 Calculate the minimum foam quantity using

 4.1 lpm/m2 application rate
 50 second discharge time (ACARP draft 90
seconds)
 Minimum AFFF Quantity (litres) = 4.1 lpm/m2 x

discharge time (sec) / 60 sec.

Step B: Cylinder Selection
50sec Discharge Time 90sec Discharge Time
Cylinder Maximum Total Max. Area Max. Nozzle Max. Area Max.
AFFF Charge of Hazard Flow Value of Hazard Nozzle
(litres) m2 m2 Flow Value
C23 18 5.0 5 - -
C30 24 7.0 7 - -
C45 35 9.9 12 4.9 5
C65 50 13.5 24 8.2 11
C106 85 19.2 44 13.8 25
 Select the cylinder which provides at least the minimum required foam
charge
 Multiple cylinders of identical size can be used to protect larger areas
 Cylinders must be located so as not subjected to in excess of 55oC
Discharge Time
 Estimate the discharge time for the system based on
cylinder and nozzles selected.
 Discharge Time (sec) = AFFF volume/discharge flow rate
 Discharge Flow Rate can be estimated from the graph (or
see formula in manual)
1.40
1.35
1.30
1.25
1.20
1.15
1.10
Discharge Flow Rate (ltrs/s)
1.05
1.00
0.95
0.90
0.85
0.80
0.75
0.70
0.65
0.60
C23
0.55
0.50 C30
0.45
0.40
0.35
C45
0.30
0.25 C65
0.20
0.15 C106
0.10
0.05
0.00
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50
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FireNozzle
Suppression
Flow Valuecopy f 46
Selecting Discharge Hose
Hose Size Volume (ltrs / m)
1/2” 0.12
3/4” 0.28
A combination of hose sizes can be used when designing a Discharge System.
For example:
1/2" Stainless Steel Tube
8x 60° angle High Flow nozzles:
Nozzle Flow Value = 16
3/4" Hose
4x 50° angle Med Flow nozzles: 10 2 2 2 2
1 1
Nozzle Flow Value = 4
20
Individual Nozzle Flow Value

Total Nozzle Flow Value
Total Nozzle Flow Value = 20
1 1
10 2 2 2 2

Hose Volume Limits
 Maximum total hose volume allowed is 5% of cylinder fill
Cylinder Maximum Hose Volume (ltrs)
C23 0.9
C30 1.2
C45 1.75
C65 2.5
C106 4.25
 Hose volume can be calculated from the following table
Hose Size Volume (ltrs / m)
1/2” 0.12
3/4” 0.28

Multiple Cylinders
 Multiple cylinder installations are

possible within maximum flow value
restriction for 3/4” hose (max. NFV
52)
 On a ROP system a maximum of

Five cylinders are permitted to be
manifolded together
 If require total flow value in excess

of 52 use separate cylinders and
discharge networks

Verifying Application Rate
 Once cylinder and nozzle selection has

been made verify that the the minimum
application rate of 4.1 lpm/m2 will be
achieved
Application Rate (ltrs/min/m2) = Total AFFF Solution (ltrs) x 60

Total Hazard Area (m2) Discharge Time (sec)
 A full system discharge test must be

completed during commissioning to determine
actual discharge times and application rates

Nozzle selection and placement.
 At this point it is important to get information from the customer on

areas that they consider to be a hazard.
 These may not be obvious to you as the installer as being likely to
cause a problem, however, the client may know of incidents having
occurred in other similar pieces of equipment.
 Measure the surface area of the hazard and the distance to the
surface from the nozzle mounting locations chosen. The
specifications should indicate the area of coverage to be expected
from each nozzle type over a given distance.

Nozzle Characteristics
 Determine the number and type of nozzles required to completely cover the
hazard area.
 Each nozzle has been assigned a Nozzle Flow Valve (NFV)
 Calculate the total system NFV and check against maximum allowable NFV for
the cylinder selected
Part No. Ref No. Discharge Discharge Range Nozzle Flow Nozzle Use
Angle Coverage Value
109476 BM17N 60° Ø1100mm 1000mm 2 General Purpose

(high flow) Nozzle.For covering
Ø550mm 500mm large area risks
117350 BM8N 50° Ø460mm 500mm 1 For covering small area

(med flow) risks
Ø230mm 250mm
119338 BM16W 120° Ø1100mm 320mm 2 For covering large area

(high flow) risks from a smaller
Ø550mm 160mm range.

Nozzle Characteristics
 The listed discharge coverage is normal to the nozzles axis and may be
proportioned for intermediate ranges.
 The listed range is the minimum effective distance.
 Multiple nozzles used to cover an extended risk area, should be placed at a
distance not greater than the discharge coverage.
 The discharge coverage is generally in the same plane as the nozzle axis and
may be considered triangular in the discharge envelope.

Nozzle Installation Tips
 Don’t place nozzle assemblies in areas likely to be stood on or interfered

with during routine maintenance activities. Inevitably, they are moved out of
alignment and will not give adequate coverage.
 Avoid using plastic nozzle caps as they are prone to melting in the heat
normally encountered in engine compartments and may not blow off when
the system discharges.
 Always ensure the nozzles and associated pipework are adequately
supported and secured. Mining vehicles and heavy equipment in general
suffer from excessive vibration, which will damage and render unserviceable
poorly installed discharge system components.

Commissioning
 Design verification & commissioning is essential to

ensure the correct operation of the system
 Each system must be subjected to a full discharge
test to confirm full coverage of the hazard and that the
required discharge time and application rates are
achieved
 Commissioning tests and checklist must be completed
and entered into the Commissioning Section of the
Quell Series II Lotus Notes database

Test an installed pre-engineered
foam fire suppression systems


 Explain why pre-testing procedures are carried out in accordance with

the requirements of the manufacturers’ instructions and specifications.
 Explain why safety procedures must be adhered to according to
organisational and customer requirements
 Testing procedures are completed according to the relevant
maintenance schedule.
 Explain the importance of recording test results accurately and legibly.

Testing procedures.
 Inspection and testing tasks usually fall into two areas of
responsibility. The tasks conducted by the owner and/or
operator, and those normally conducted by qualified competent
technicians.
 Pre-engineered foam fire suppression systems are typically
installed on heavy diesel equipment due to the higher potential
risk of a fire occurring. Therefore, most pre-engineered foam fire
suppression system manufacturers have nominated in their
maintenance specifications that inspection cycles are also
performed at hourly intervals. In addition, the manufacturer will
usually nominate that service intervals are carried within a
minimum timeframe to ensure the installed fire system is kept in
good working order. For example: Equipment that may be used
occasionally or be out of use for an extended period of time.

Maintenance Schedules
Interval: Performed by: Records:
10 service hours or Daily Operator / Owner / None, unless requested from owner
Maintainer / Manufacturer
Every 50 service hours or Operator / Owner / None, unless requested from owner
weekly Maintainer / Manufacturer
Every 1000 service hours or 6 Maintainer / Manufacturer Service Report / Logbook and
monthly service record tag (Level 1)
Every 2000 service hours or Maintainer / Manufacturer Service Report / Logbook and
12 monthly service record tag (Level 2)

Identifying maintenance
requirements
In order to determine what schedule of service is due on a vehicle, you should
always check the maintenance record tag and cylinder identification plate.
According to AS1851.1 and AS/NZS1851.13 the periods for maintenance
schedules are as below:
 Level 1 - 6 monthly
 Level 2 - Yearly
 Level 3 - 3 yearly
 Level 4 - 6 yearly
 Level 5 - After extinguisher use.
These levels apply to all portable and wheeled fire extinguishers EXCEPT
those, which are permanently located in an AGGRESSIVE
ENVIRONMENT.

requirements
Not all of the service levels of AS1851.1 and AS/NZS1851.13 can be
applied to pre-engineered foam fire suppression systems.
For example:
Existing schedules Can be used Reason for use.
Level 1 - 6 monthly Yes Relates to Manufacturer’s specifications for
1000hrs or 6 monthly.
Level 2 - Yearly Yes Relates to Manufacturer’s specifications for

2000hrs or 12 monthly.
Level 3 - 3 yearly No No Manufacturer’s specification.

Level 4 - 6 yearly No No Manufacturer’s specification. Can be carried out on
cylinder only. The cylinder is stamped by a
licensed test station.
Level 5 - After Yes Can be used. Although, the tasks that are carried out,
extinguisher use. are usually identical to a 2000hrs or 12 monthly
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test. copy f 61
requirements
 Check Service date Tag and
Cylinder I.D. plate
 Cylinders have a periodic

inspection and test every 5
years to AS2337.1. This
test should be carried out
by a licensed test station.

Session 2 Learning outcomes review:
Now you have successfully completed

this unit, you should be able:
 Explain why pre-testing procedures are carried out in accordance

with the requirements of the manufacturers’ instructions and
specifications.
 Explain why safety procedures must be adhered to according to
organisational and customer requirements
 Testing procedures are completed according to the relevant
maintenance schedule.
 Explain the importance of recording test results accurately and
legibly.
If you can’t, don’t worry.

Just
3 review the information or seerom
your trainer
Chubb Firefor more help.
PRMPFES27A

 Describe how a pre-engineered foam fire suppression system in

maintained according to the requirements of the relevant schedule.
 Explain how faulty equipment is reported, repaired or replaced
according to organisational procedures, customer requirements and
technical specifications.
 Explain the importance of adhering to safety procedures according to
organisational and customer requirements.
 Complete and distribute all maintenance documentation in accordance
with organisational procedures and customer requirements.

Every 10 Service Hours or Daily
 System Pressure
 Fire Alarm Panels
 Pull Pins
 Manual Actuators
 Optical Detectors

Every 50 Service Hours or Weekly
 Cylinder Valves
 Nozzle Caps
 Pipework, Hoses and Fittings
 Cylinders
 Cylinder Brackets

Every 1000 service hours or 6 months
(Level 1):
 Labels
 Discharge Pipework
 Manual Co2 Actuators
 Actuation Pipework

Every 2000 service hours or 12 months
(Level 2):
 Discharge Test
 Cylinder Inspection
 Cylinder Valves
 Pyrotube Wick & LOP Detection Tubing
 Manual Actuators
 Refill & Pressurise System

Maintenance Flow Chart


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PRM30400: Certificate III in Asset

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When you have successfully

 Explain the requirements for work permits at a customers’ site.

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All monitored systems (Fitted with

Detected by operator Detected by auto activation Detected by device.

Operator alerted. Fire system activated.

Fire Alarm activates Operator alerted.

Engine Shutdown initiated Engine Shutdown initiated

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1. Rise of Pressure. (ROP)

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1. Kenaikan pressure dari suatu alat

2. Releases the stored pressure and

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1. Loss of Pressure from a remote device

2. Releases the stored pressure and

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Rise of Pressure Loss of Pressure

 Chrome Plated Brass

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Flexible - allows for vertical or horizontal

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Cylinder C23 C30 C45 C65 C106

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 Nozzle Kits can be altered to

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– avoid close proximity to turbo chargers

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 Used in conjunction with

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 Manifold Block used to

 Check Valves required at

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¼" O-RING FACE

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AERATED FOAM SOLUTION IN ACTION

NON-AERATED FOAM SOLUTION APPLICATION

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PART DESCRIPTION TOTA WATE AFFF PRESSURE HEIG

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 A Risk Assessment section is provided in the Quell Series II

 In undertaking a risk assessment, it is essential that input is obtained

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