Industrial foam fire suppression systems
Foam fire suppression systems are often an excellent alternative to classic water systems. Foam (or more precisely, a water-foam solution is much lighter than water. Therefore, for some flammable substances, a foam suppression system is more effective than other extinguishing systems. At the same time, the installation does not burden the structure of industrial buildings as much as water-based fire extinguishing devices.
Our team has extensive experience in industrial fire and explosion safety projects (including wood, food and energy manufacturing, as well as waste processing). We know how to manage the assembly teams to protect the plant from losses (suspension of production, product contamination, damage to machines, etc.). We design and install foam installations in accordance with the guidelines of VdS, PN-EN, NFPA, or FM GLOBAL , depending on the requirements of your insurer.
VARIETY OF INDUSTRIAL FACILITIES
- power engineering
- wood industry
- food industry
- waste processing
- chemical & petrochemical industry
- other
COMPLIANCE
WITH STRICT REQUIREMENTS
- PN-EN
- VdS
- FM Global
- NFPA
FAMILIARITY WITH DIFFICULT WORKING CONDITIONS
We know the challenges of industrial plants inside-out!
We will match industry-specific components to your working environment
We completed hundreds of industrial projects, including in the corrosive C5M/C5-I environment!
VERSATILITY OF FIRE SUPPRESSION AND DETECTION SOLUTIONS
Hydrant installations, pumping stations, water tanks
We can meet your insurer’s requirements together!
IIt is the insurance audits and their follow-up requirements for manufacturing companies that often bring clients to us. Regardless of the requirements set by your insurer, we can meet them all.
Foam installations are best suited to protect:
Waste sorting and recycling plants
Flammable liquids and chemicals
Plastics processing plants
Plants processing metals and hazardous materials
Large tanks
Large industrial areas
Industrial plant vs shopping mall: what’s the difference in fire protection?
Installation of foam systems (and other fire protection installations) in an industrial facility is quite unlike setting up one in a commercial or office facility. For details, see below:
| THE CHALLENGE | COMMERCIAL FACILITIES | INDUSTRIAL FACILITIES | ||
|---|---|---|---|---|
| Risk of disruption to the facility's operation during assembly | None, or minimal. Mist systems are most often installed at the construction of the facility, or outside normal operating hours. | Large or high. Assembly is most often carried out during normal operation of the facility Therefore, practical experience in plants is important to minimize this risk. | ||
| Access to scaffolding, trolleys and lifts | Free. Most often the space is free of clutter, and scaffolding, trolleys and lifts can be used without any problems. | Significantly restricted. Tightly packed production halls offer limited access to mist system installation points. | ||
| Risk of collision of the constructed water mist extinguishing system with the infrastructure of the production hall | Zero or minimal. The space is still undeveloped, the assembly team has much freedom of movement. | High. The existing devices and auxiliary installations, often high-rise, hinder assembly works. | ||
| Occupational health and safety regime | The work is carried out in the standard OHS regime. | The work is subject to a high health and safety regime, which requires arrangements and clearance for work. |
CASE STUDIES
Fire suppression systems of our clients
AW-OZ: new approach to explosion risk assessment
Andrzej Wolff, Ph.D., has developed AW-OZ, a novel method for assessing the hazards of typical industrial equipment and installations used in the processing of bulk materials. The AW-OZ approach is based on the design, operating conditions of the equipment and the presence of combustible and explosive dust. In the realm of industrial safety, the limitations of the current explosion risk assessment methodologies, mandated by the ATEX Directive have become increasingly apparent. Recognizing these shortcomings, Dr. Andrzej Wolff proposes a groundbreaking methodology that shifts the focus from probability-based assessments to a more objective analysis grounded in process data. What are the nuances of this new methodology and what is its potential to revolutionize explosion risk management? Limitations of the now recommended explosion risk assessment: the legal status The need to assess the risk of explosion in production conditions threatened by the presence of flammable and explosive gases, dusts, mists, vapors of flammable liquids and fibers results from the provisions of the ATEX Users Directive (99/92/EC). According to the Directive, explosion risk assessment related to explosive atmosphere in workplaces should take into account the following: probability and duration of an explosive atmosphere, likelihood of both occurrence and activation of ignition sources, including electrostatic discharges, installations operated by the employer, substances and mixtures used production processes involved, and their interactions the magnitude of the anticipated consequences of an explosion In practice, the explosion risk assessment techniques used mainly emphasize the evaluation of the probability of an explosive atmosphere, the probability of occurrence and activation [...]
Lighter, safer, faster fire protection: fireproofing a biomass conveyor with a water mist extinguisher
Project challenges The switch from coal fuel to a mixture of coal with more ignitable and explosive biomass increased the risks of fire and explosion in the power The investor had to decide between two effective fire protection techniques to select the most suitable option for their conveyor belt. The decisive factors were: the weight of the system and the time needed for installation. The solution: To reduce the risk of structural overload on the conveyors, a mist fire extinguisher was selected over a traditional sprinkler system. Unlike the nozzle system, the mist fire extinguishing system did not require a building permit. The mist system's lower water usage not only prevented potential water damage and reduced the risk of flooding, but also allowed for quicker resumption of operations post-incident. The design and installation of a fire protection system for belt conveyors was part of a large modernization project we completed for two power plants in Poland. The need to improve fire and explosion safety in these facilities resulted from changing the fuel from coal to a mixture of coal with biomass, much more easily ignitable and explosive. Apparently, the investor wanted to avoid disasters such as those that affected other plants in Poland in the past, and the Ridderskaya Test plant in Ridder, East Kazakhstan, in 2023. However, before we were commissioned, our experts took part in a number of consultations. They were requested to recommend optimal safety systems, including extinguishing techniques for conveyor belts. The investor, a large European [...]
Over-sensitive fire detection and alarm system: how to solve the problem and… save as much as 40% of costs?
Want to optimize a fire system? Instead of blindly following the norms, run expert field tests. A polyurethane foam manufacturer invested EUR 2,500 in tests. Their savings reached several times that amount compared to the total project estimate! (Yet another) manufacturing plant came to us with a problem of false activation of a fire suppression system. Unfortunately, such incidents are quite common in industry. They cause dozens of thousands of euro-worth losses every year (cost of cleaning, lost product, etc.). In plants where such situations occur even several times a year, costs can easily reach several hundred thousand euro. No wonder, then, that the idea of turning off a "hypersensitive" system for the sake of savings seems all too tempting. However, what about the fire hazard? In case of a real fire emergency not only do you risk serious losses, but your insurer can refuse compensation. So is there anything you can do to make the system respond only in the event of actual threat? It takes two types of detectors to properly detect fire This time, the problem of an oversensitive fire detection system involved a polyurethane foam plant. The “culprit" was a system based on aspirating smoke detectors (ASD). This type of sensor samples air in various inaccessible places without depending for detection on the convective movement of smoke. These detectors are known for their effectiveness where the highest sensitivity of detection is a must. They detect fire hazard in fraction of a second. This makes them extra [...]
How do foam installations work?
In our foam installations, the extinguishing agent is foam created by mixing a special agent and water. Depending on the nature of the protected area or tank, and the hazardous substance, one of three types of foam is selected: heavy, medium, or light.
The most often used foam in industry is the heavy type. Its consistency is runny, or viscous, than other types of fire extinguishing foams. At the same time it is much less runny than ordinary water.
How industrial foam systems extinguish fire?
Foam installations cool the flames and flammable material by allowing for a longer contact of foam than in the case of water. The “crust” that forms between the fire and the air eliminates the oxidant and the combustible material, which had not yet caught fire.
There are 3 types of foam: light, medium and heavy:
- heavy foam – expansion ratio up to 20, most often used to extinguish large spaces, e.g., production halls or warehouses, in a short time
- medium foam – expansion ratio from 20 to 200, most often used where a fire can occur low by the floor, e.g., in a plastic warehouse)
- light foam – expansion ratio from 200 to 1000, most often used to extinguish flammable liquids in spilled tanks (the foam is spread on the surface of the burning liquid, cutting off the air supply and lowering its temperature)
How foam is stored and generated?
Contrary to water systems, which require storing large amounts of water for the extinguishing process, foam installation, requires less water. However, a foam installation requires another tank for the foam concentrate.
Water flows from the fire protection tank through a pipeline next to the foam concentrate tank and enters the dispenser. For example, a VRC dispenser reduces the diameter of the water flow to increase pressure. Then it simultaneously supplies a specified amount of foam concentrate, which is then injected to the narrowed water flow creating a water-foam solution.
Foam systems: nozzles or monitors?
Similarly to mist installations, foam systems can consist of both closed nozzles (wet or dry configuration) and open sprinklers. You can also use water and foam monitors, which spray foam under pressure over the entire surface and can supply up to 100 times more foam per minute.
Is there other purpose for foam systems than fire suppression?
Foam fire extinguishing systems can be designed and installed not only to extinguish a fire, but also (or solely) to perform other protective functions. What are the differences in foam installations for extinguishing and for cooling?
EXTINGUISHING
Foam is the basic extinguishing agent for many substances that cannot be put out with water (e.g., flammable liquids). Hence, its widely used for fire extinguishing purposes.
Foam is also useful in extinguishing plastics and similar flammable materials, or in the case when the fuel material mixture is difficult to determine.
COOLING
Creates a preventive layer of foam the on flammable material that has not yet been reached by fire to insulate it from flames and heat.
For example, pouring foam over the top of a flammable liquid tank prevents the liquid from igniting by the approaching fire.
Hassle-free assembling of the foam system
We understand that production processes such as manufacturing, packaging, or storage are key to production profit. That is why we assemble fire extinguishing foam installations in such a way as to minimize disruption to the production process.
Based on experience, we anticipate potential challenges already in the design phase, and solve them. We know how to cooperate effectively with production managers to coordinate the assembly process. Our installation operations are scheduled only for specific days and times. We adapt to planned production downtime or periods of reduced work intensity. When necessary, we work at night. We always adapt our work methods to the character of the production plant.
ASSEMBLY WORKS IN PRACTICE
We eliminate production downtime, or bring it down to a minimum
We coordinate assembly with the production schedule
We organize the necessary equipment, e.g. aerial lifts/scaffolding/climbers
We adhere to all internal procedures of the plant
If necessary, we also work at night and on weekends
We only move and work within clearance zones
Before assembly, we secure machines and devices
After installation, we clean up and make sure regular production is quickly restored
Ensuring property safety
At every stage of our operations, the safety of your assets in halls, warehouses and other production spaces, is crucial for us. We are aware that any damage we cause can have repercussions for the continuity of production and take caution to prevent such situations.
BEFORE THE ASSEMBLY
We agree on the scope of work with the investor
We familiarize ourselves with the safety guidelines
We secure the workplace
We cover machines and devices
DURING AND AFTER ASSEMBLY
We move about with utmost caution
We secure property from damage
We clean the site thoroughly afterwards
We enable production to be restored immediately
- developing the concept and necessary blueprints
- selecting and delivering key installation elements
- developing and implementing a control system
- visualizing the water mist system
- integration of the system with existing security systems
In addition to foam systems, we design and implement complete, integrated fire protection systems (for a full list see below). Importantly, our operations can include all, or only selected of the points mentioned, as needed. If necessary, we integrate the delivered systems with existing solutions.
- Fire alarm system (SAP, SSP), wired and wireless
- Fire detection system
- Ventilation and smoke extraction systems
- CCTV monitoring system
- Intruder alarm system
- Sound warning system
- Access control and work time registration systems
- Emergency and evacuation lighting
Plastics melt when exposed to fire, forming a tight shell. Why is foam extinguishing more effective than water in such situations? It is all about surface tension. Water without the addition of a foaming agent has high surface tension. For example, if a smoldering pile of waste is flooded with water, it cannot be extinguished as water cannot penetrate inside, where a fire usually occurs. By adding a foaming agent, we lower surface tension. Foam penetrates the pile and reaches the fire.
Systemy gaszenia mgłą wodną mogą osiągać wymagane ciśnienie rozpylania przez zasilanie ze zwykłych zbiorników z wodą ppoż. i dobranych odpowiednio pomp, lub także przy użyciu jednego lub wielu zbiorników wypełnionych wodą pod ciśnieniem.
Pompy to praktyczne rozwiązanie, zapewniające stałe, wysokie ciśnienie mgły wodnej w trakcie akcji gaśniczej. W przypadku mniejszych powierzchni, a tym samym mniejszego zapotrzebowania na wodę, można rozważyć rezygnację z budowy pompowni na rzecz zbiorników wypełnionych wodą pod ciśnieniem. Koszty takiej inwestycji z dużym prawdopodobieństwem będą niższe, jednakże należy wziąć pod uwagę, że takie źródło wody dedykowane jest najczęściej do jednej strefy gaśniczej. Więcej stref gaśniczych w jednym obiekcie może spowodować, ze efekt ekonomiczny przesunie się w stronę systemu pompowego.
Technologię mgły wodnej stosuje się w takich gałęziach przemysłu jak energetyka zawodowa (elektrownie i elektrociepłownie) włącznie ze stacjami transformatorowymi, oraz m.in. w przemyśle petrochemicznym. Oprócz konkretnych branż są to także systemy gaśnicze, które można szerzej zastosować w ochronie tuneli kablowych, sterowni, linii produkcyjnych, magazynów, czy maszynowni.
- W sytuacjach, kiedy skuteczność systemu mgły wodnej nie jest wystarczająco udowodniona – np. testy skuteczności działania dysz w akredytowanym laboratorium nie wyjdą pozytywnie
- W sytuacjach, kiedy tańsze i równie skuteczne są inne rozwiązania, a głównym kryterium zakupu jest cena, a nie np. konieczność zużycia do gaszenia jak najmniejszej ilości wody, przez obawę przed zniszczeniem parku maszynowego, długim przestojem produkcji po gaszeniu zwykłą wodą itp.
