Effective: 10/21/11 Page 1 of 17 Rev. by J. Shively Fire Water Utility 2002 Training Manual Raw Water Storage Area Document Revision Change Table Revision Number Revision Description Revised By Revision Date Rev. 01 Considered as starting document for revision change table 2011-0 added the new CV system for A-445 J. Shively 10/21/11 BASF CORPORATION AGRICULTURE PRODUCTS BEAUMONT PLANT Approved By:
Effective: 10/21/11 Page 2 of 17 Rev. by J. Shively Purpose To provide information about the Firewater Utility located at the Raw-Water Storage Area. The Firewater system is designed to utilize raw water from the LNVA canal, and provide raw-water to the Beaumont Complex though an underground header system for fire fighting in sufficiently high volume and pressure to ensure the safety of personnel and equipment.
Effective: 10/21/11 Page 3 of 17 Rev. by J. Shively Major Equipment LNVA Canal (Dicamba Owner) Canal Water Lift Pumps A-490A\B (Dicamba Owner) Fire Water Jockey Pump A-445A Electric Firewater Pump A-441A An open canal which is used as a means to transfer raw water from an external source to the plant site, and provide a reservoir for the firewater Spared Off Site 100 Hp, 900 GPM, Variable Speed pumps that are used to lift raw water from LNVA Canal to the Raw Water Storage canal. A 500 GPM electric, centrifugal pump that constantly maintains the 150 lb. pressure on the fire water distribution header A larger 1,500 GPM volume, electric, centrifugal pump that is utilized when the Jockey pump is no longer able to maintain firewater header line pressure. Diesel Firewater Pump A-441B A 2,000 G.P.M, Diesel powered, centrifugal pump that is utilized when the Jockey pump and the A-441A & C electric firewater pumps are no longer able to maintain firewater header line pressure, or when there is no electrical supply to the electric firewater pumps
Effective: 10/21/11 Page 4 of 17 Rev. by J. Shively Major Equipment (Continued) Electric Firewater Pump C-441C Electric Firewater Pump A-441D Secondary Diesel Firewater Pump A-441E Diesel Fuel Tanks for A-441B&E Diesel Firewater Pumps A second 1,500 GPM volume, electric, centrifugal pump that is utilized when the Jockey pump and A-441-A is no longer able to maintain firewater header line pressure. A Third 1,500 GPM volume, electric, centrifugal pump that is utilized when the Jockey pump, the A-441 A, B, and C is no longer able to maintain firewater header line pressure. A second 2,000 G.P.M., Diesel powered, centrifugal pump that is utilized when the Jockey pump, the 3 electric Firewater pumps, and the A-441-B Diesel pump are no longer able to maintain firewater header line pressure. Two 500-Gallon Tanks, fuel storage for each diesel firewater pump Diesel Storage Tank & Electric Diesel Transfer Pump One 2050-Gallon Tank to provide refueling capability for A-441B&E fuel tanks. A electric pump is used to transfer diesel from storage to fuel tanks
Effective: 10/21/11 Page 5 of 17 Rev. by J. Shively Major Equipment (Continued) Fire Water Distribution Header Fire Hydrants Post Indicator Valves (Fire water isolation valves) Fire Water Monitors Fire Water Deluge System(s) Fire Water Sprinkler System(s) A network of underground piping that distributes firewater throughout the plant site. This header loops around the site with multiple entry points to each unit A fire water line riser and valve with hook up capabilities for the Fire Truck of Portable Fire fighting equipment and hoses. A block valve with a stem above ground and post indicators that allow the underground firewater lines to be opened or closed as required. A fire water line riser with a permanently mounted spray nozzle capable of spaying directional water and foam. These monitors are strategically placed throughout the plant to cover areas that contain flammables Seven dry riser type water dispersion systems located at: Dicamba Unit, DMTA Unit, MPP Unit, Pilot Plant, Site Flammable Drum Storage, W.O.D. Unit. Four wet riser type water dispersion systems located at: Pack-out Warehouse, MPP Warehouse, Pilot Plant Drum Storage, W.O.D. Hazardous Storage Warehouse
Effective: 10/21/11 Page 6 of 17 Rev. by J. Shively How It Works The Lower Neches Valley Authority pumps raw water from the Neches River to a distribution canal located on West Port Arthur Road. About a mile south of our plant, we have a lift station which pumps the water from the LNVA canal, via A-490 A\B, to hold a level in the Raw Water Storage Canal. In case of a fire the lift pumps must be monitored to ensure that a sufficient supply of raw water is maintained in the storage canal. All firewater pumps take suction from a 14-foot deep suction sump, which is gravity filled from the raw water storage canal. A screen prevents trash from entering the suction sump from the storage canal. This screen must be cleaned as necessary, to ensure proper flow to the suction sump. Normal operation of the firewater system utilizes only the A-445 jockey pump to keep the firewater distribution header charged to 150 psig Therefore firewater should not be used for any other purpose other than fighting fire, without first checking with the W.O.D. Control Operator. NOTE: 1. Pressure is let down from the header in 2 steps to avoid cavitation in the control valves 2. Instrument air 3-way valve should be set to "Control" on both controllers normally 3. PV-G441A (1st valve off header) is adjusted to control header pressure (PI-xxx?) at 150 psig Note: Setting on controller is slightly off, so set at 140 psig on current controller 4. PV-G441B (2nd valve, by reservoir) is adjusted to 75 psig (Range 50 to 85 psig). This setting was chosen for more stable control of the system. 5. Note: Both control valves are fail closed to assure firewater supply to header in case of instrument air failure. 4. Unusual operations: If a controller is not working, the valves can controlled manually by: a. Set 3 way valve to inoperative controller "Manual" (instead of "control b. Adjust regulator pressure to set valve position (higher pressure = more open) If the firewater header pressure falls below 143 psig for 10 seconds, then a lowpressure switch starts the larger electric pump A-441A. If the firewater header pressure falls below 140psig for 20 seconds, then a lowpressure switch starts the second electric pump A-441C. If the headed pressure falls below 135 psig, then the low pressure switch activates a 60 second delay, which then starts the Diesel powered pump, A- 441B.
Effective: 10/21/11 Page 7 of 17 Rev. by J. Shively If the firewater header pressure falls below 130 psig for 20 seconds, then a lowpressure switch starts the third electric pump A-441D. If the headed pressure continues to fall and falls below 125 psig, then the low pressure switch activates a 120 second delay, which then starts the secondary diesel pump A-441E.
Effective: 10/21/11 Page 8 of 17 Rev. by J. Shively How It Works (Continued) The diesel pumps are electrically started by storage batteries. A continuous charger maintains the batteries. Starting of the Jockey pump is manual, and the automatic startup of the five back up firewater pumps are sequenced to start as follows Electric Jockey Pump A-445-500 gpm (Continuous run) 1) Electric Pump A441-A - 1500 gpm (143psi @ 10 second delay start) 2) Electric Pump A441-C - 1500 gpm (140psi @ 20 second delay start) 3) Diesel Pump A441-B - 2000 gpm (135psi @ 60 second delay start) 4) Electric Pump A441-D - 1500 gpm (130psi @ 20 second delay start) 5) Diesel Pump A441-E - 2000 gpm (125psi @ 120 second delay start) Special Note If the demand for firewater is so great that the pressure of the firewater system should fall below 130 psig suddenly and stay, the automatic start sequence would change to A-441D pump starting ahead of A-441B due to its shorter time delay start. Electric Jockey Pump A-445-500 gpm (Continuous run) 1) Electric Pump A441-A - 1500 gpm (143psi @ 10 second delay start) 2) Electric Pump A441-C - 1500 gpm (140psi @ 20 second delay start) 3) Electric Pump A441-D - 1500 gpm (130psi @ 20 second delay start) 4) Diesel Pump A441-B - 2000 gpm (135psi @ 60 second delay start) 5) Diesel Pump A441-E - 2000 gpm (125psi @ 120 second delay start) A sufficient Level of Diesel fuel must be maintained in each 500-gal fuel tank. The level should be maintained at lest 2/3 s full (no less than 333 gallons). Refuel as needed from the 2050-gallon diesel storage tank using the electric fuel transfer pump.
Effective: 10/21/11 Page 9 of 17 Rev. by J. Shively How It Works (Continued) The site firewater distribution header system is set up in a loop system so that firewater can be delivered to all site locations from opposite sides of each user. This ensures that no unit is without firewater in case of line damage. The bad section of line can be isolated for repair with out shutdown of the entire header. From the Firewater Header, water is supplied to all the units and is utilized by numerous pieces of fire fighting equipment. These pieces of equipment are fully covered in the module covering the area in which they are located. Most process areas, warehouses, cooling towers, and flammable storage areas have a deluge/sprinkler system. Though each units deluge/sprinkler system may be different in some ways, they all operate in the same basic manner.
Effective: 10/21/11 Page 10 of 17 Rev. by J. Shively DRY SYSTEM Activation Instrument Air pressure on a pneumatic system holds a flapper valve closed. The flapper valve blocks firewater flow to the spray water header. When a melting sensor releases air pressure or a manual pull station is activated to release air pressurre, the flapper valve opens. This allows firewater to enter the spray water header. The spray water header distributes the firewater to a set of fixed sprinkler heads The sprinkler heads are arranged to distribute a pattern of water over a large area and distribute sufficient amount of water for fire suppression and/or cooling to all equipment located within the activated system. Shutdown These deluge/sprinkler systems have to be manually reset each time that they are activated. Manually block in the valve located in the deluge house(s) when firewater is no longer needed and contact EH&S Department for resetting of deluge valve(s). WET SYSTEM Activation The wet sprinkler system is liquid full system of firewater at all times. The system is held at firewater supply pressure (150psi). This system does not operate under instrument air and does not use a flapper valve to activate. Instead special melting sensors are attached to each sprinkler head, which are located all along the coverage area. When needed this type of sprinkler head will activate under a set temperature, which will allow the firewater to spray only from that particular sprinkler head and apply firewater where needed. Shutdown Manually block in the valve located at the riser for sprinkler system when firewater is no longer needed and contact EH&S Department for repair of activated sprinkler heads by approved contractor so the system may be repaired, inspected, and approved for service.
Effective: 10/21/11 Page 11 of 17 Rev. by J. Shively How It Is Controlled Raw Water Storage Canal Level Firewater Header Pressure Low Load Conditions (High Pressure) Firewater Header Pressure High Load Conditions (Low Pressure) Startup and Shutdown of Firewater pumps Manually Controlled by adjusting the speed of the A-490A/B Lift Pumps (Dicamba Owner) Automatically controlled by a local Pneumatic Controller, which adjusts the amount of kickback from the discharge of the Jockey Pump to the canal Automatically controlled by pre-set low-pressure switches starting additional firewater pumps as required to hold header pressure. Start-Up is automatically controlled by the Metron Switch-Gear Controllers when the controllers are in Automatic. There are also manual start switches located at each pump. Shutdown of firewater pumps must be manual at the Metron Switch- Gear Controllers.
Effective: 10/21/11 Page 12 of 17 Rev. by J. Shively Safety Devices PSV-A-441A Firewater Header Pressure Relief Valve PSV-A-441D Firewater Pump Pressure Control/Relief Valve PSV-A-441E Firewater Pump Pressure Control/Relief Valve Water-Hammer Prevention Device Air Trapped Riser Firewater header pressure relief valve, which starts to relieve excess pressure at 165 psig (fully opens at 125% of setting = 206 psig) and discharges back to the canal to prevent over pressuring the firewater lines. A-441A, A-441B, & A-441C are all users of this PSV Relief valve set at 180 psig Discharges back to the canal to prevent over pressuring the firewater pump A-441D Relief valve set at 165 psig Discharges back to the canal to prevent over pressuring the firewater pump A-441E A 6-inch pipe air trap riser located Northeast of the Pack-Out Warehouse. This system is designed to prevent water hammering to the underground firewater lines.
Effective: 10/21/11 Page 13 of 17 Rev. by J. Shively Alarms RL 4976 RL 4312 RL-G441-E Firewater System Failure Alarm Run Light triggers a Visual and Audible alarm in the boiler house is activated when the electric firewater pump A-441A starts. Run Light triggers a Visual and Audible alarm in the boiler house is activated when the diesel firewater pump A-441B starts. Run Light triggers a Visual and Audible alarm in the boiler house is activated when the secondary diesel firewater pump A-441E starts. A Visual and Audible alarm in the boiler house is activated when A441E does not start by low pressure switch activation
Effective: 10/21/11 Page 14 of 17 Rev. by J. Shively New Diesel Firewater Engine Controls A-441E (2000 GPM) Overview The new diesel-driven firewater pump was installed to accommodate the increased demand for firewater by the construction of the SAN582H (otherwise known as DMTA) unit. This pump ties into the existing firewater system and is located in the same general area as the other firewater pumps by the canal. Two banks of batteries supply cranking power for the engine. Diesel fuel is located in a separate area a short distance away from the panel. The main control panel is located on the same skid as the engine, opposite the drive-shaft end of the engine. Panel Operation Selector Switch Positions Test In this position, the water pressure is momentarily dropped, causing closure of the low-pressure switch, starting the engine. Putting the switch in test energizes a solenoid located outside and to the lower left of the panel. This solenoid drains the piping going to the pressure switches that control the engine. An orifice located in this piping accomplishes the drop in pressure with minimal water flow to the skid. Auto In this position, the controller is in standby mode. All automatic functions are ready for operation. This is the normal position for the selector switch. Off In the off position, automatic and manual start functions are disconnected. Battery power is still available to the controller and the engine can still be started using the local start levers, but starting from the main panel is not possible.
Effective: 10/21/11 Page 15 of 17 Rev. by J. Shively New Diesel Firewater Engine Controls A-441E (2000 GPM) (Continued) Manual When in the manual position, all automatic functions of the controller are bypassed when started with manual push buttons. Two manual start push buttons are provided for manually cranking the engine from either set of batteries. Both switches may be depressed simultaneously, increasing battery voltage in the event of poor battery condition. All alarms are operative in manual. Manual Stop Push-button This button is mounted outside the controller panel above the door. The button bypasses the selector switch and stops the engine if the firewater pressure is above the start point. After the engine stops, it is automatically reset for standby mode. Automatic Weekly Test A 7-day program clock is provided that can be set to give automatic test runs on any day of the week and anytime of the day desired. Any demand signal will override the automatic shutdown of this feature. The clock opens the solenoid drain valve momentarily, relieving pressure to the pressure switch, exactly as if the selector switch were in the test position as mentioned above. This drop in pressure starts the engine and the clock times the length of the test run, 30 minutes being the recommended duration. Please note that BASF has elected not to use this feature, but elects that testing be performed manually.
Effective: 10/21/11 Page 16 of 17 Rev. by J. Shively New Diesel Firewater Engine Controls A-441E (2000 GPM) (Continued) Engine Starting Alternate Starting When an automatic start is requested, the controller cranks from one set of batteries for fifteen seconds. Should the engine fail to start during this period, the controller waits fifteen seconds before making a second attempt to start the engine, this time using the other set of batteries. Subsequent attempts to start the engine are made in the same manner as the first two until a total of 6 attempts are made. After the sixth attempt, the over-crank lamp will be lit and the audible alarm will sound. Battery Failure Lockout Should one set of batteries fall below 60% of its rated voltage during cranking, the controller will automatically lock on to the other set of batteries for the remaining cranking cycles. The appropriate battery lamp located above the panel door will go out. Alarms XL-G441E (Engine Running) This alarm is annunciated in the boiler control room whenever the engine is started, whatever the reason. This alarm does not necessarily indicate a low firewater pressure. This alarm could be caused by any one of the following: Someone is performing a test of the firewater engine. Power to the panel was lost. A manual start was made. One of the starting levers was pulled. System firewater pressure dropped below the low set point. A failure in the control system has occurred.
Effective: 10/21/11 Page 17 of 17 Rev. by J. Shively New Diesel Firewater Engine Controls A-441E (2000 GPM) (Continued) CA-G441E (System Failure) This alarm is annunciated in the boiler control room whenever the control panel senses certain failures as follows: Low oil pressure after the engine is running. The LED above terminal #4 in the panel indicates this. This alarm condition does not cause the engine to stop running. It will continue to run until it stops normally or is destroyed due to lack of lubrication. The engine over-speeds. The appropriate light above the panel door indicates this. This is the only control system problem, which will stop the engine. All other problems merely set off this alarm. Water temperature. The appropriate light above the panel door indicates this. This will not stop the engine. It will continue to run until it stops normally or is destroyed by excessive heat. Too many attempts to start engine (over-crank). The light above the door to the panel indicates this. Loss of a battery bank. This will be indicated by one of the battery lights above the door. If the light is on, the battery is O.K. Loss of the battery charger. The appropriate light above the panel door indicates this. As noted before, this will eventually cause the engine to attempt to start.