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PIRELLI TYRE S.p.A.PROJECT: 13003

DOC.NO.: 13003-M-FF-00-RT-1000-TO

INDONESIA MOTO PLANTDATE: 04/04/2013

PAGE: 1 PAGE : 28

PIRELLI TYRE

Subang Moto Plant report design

GUIDELINE FOR DESIGNING A FIRE

PROTECTION SYSTEMS ACCORDING TO FM

GLOBAL SPECIFICATIONS

13003-M-FF-00-RT-1000-TO

TO 04/04/2013 Design for Tender PG IM AZ

REV. DATE DESCRIPTIONPAGES PREPARED

BY

CHECKED BY

AUTHORIZED BY

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INDEX

1 SCOPE OF THE DOCUMENT 3

2 DESCRIPTION OF THE AREAS TO BE PROTECTED 3

3 REFERENCE STANDARDS AND PROJECT DOCUMENTS 6

4 STRUCTURAL DESIGN SPECIFICATIONS 8

5 FIRE FIGHTING SYSTEMS DESIGN 9

5.1 SPRINKLER SYSTEMS DESIGN 9

5.2 HYDRANTS SYSTEMS DESIGN 16

5.3 WATER SUPPLY AND PUMP STATION SPECIFICATIONS 19

5.4 UNDERGROUND AND ABOVEGROUND MAINS 27

5.5 ALARMS SIGNALS AND MANAGEMENT 31

6 FLAMMABLE LIQUID STORAGE 32

7 SMOKE DETECTION SYSTEMS 32

8 HYDRAULIC CALCULATIONS 33

9 OTHER TOPICS TO IMPROVE 33

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1 SCOPE OF THE DOCUMENT

The scope of this report is to provide a guidel ine to better understand FM Global

standard s and on ly with t he a i m to prov ide t echn i ca l su gge st ion s fo r d e s i g n

i n g fire protection systems that will be installed to protect the new Pirelli tyre plant, located in

Subang (Indonesia).

This document defines the basic requirements to elaborate preliminary Fire Protection Systems.

Each information must be verified by contractor with reference to FM Global Standards. The

document only refer to FM global standards and don’t take into account the applicable Indonesia

Law.

All the specifications described in the following paragraphs are only indicative and reflect current

requirements, so they may be subject to changes / additions in the future and they must be

mandatory verified by contractor, in order to develop preliminary fire protection project design,

that must necessarily comply with FM Global standards, as requested.

2 DESCRIPTION OF THE AREAS TO BE PROTECTED

The new plant, dedicate to produce Moto tyre, is located at the Subang area in Jakarta region.

The plant cover a total area of about 51,000 m2 ,main building including officies, facilty, and

utilities building production.

Specifically, the spaces to be protected, inside the main building area, are the following:

Mixing room building 101;

Raw material warehouse building 101

Semifinishing building 102

Tyre building 103

Curing building 104

Finishing building 105

Warehouse building 106

Indoor test Building 107

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Internal Electrical secondary with transformers MV/LV

Internal room with UPS for officies

Fire pumping station room;

Offices, Laboratories, Toilets, Canteen, infirmary

M u s h o l l a

W a s t e Storage area

3 REFERENCE STANDARDS AND PROJECT DOCUMENTS

The fire protection systems project must be prepared according to Factory Mutual reference standards and specifically according to the following applicable standards (master standards but not exhaustive list):

FM data sheets 2-0 - INSTALLATION GUIDELINES FOR AUTOMATIC SPRINKLERS

FM data sheet 3-7 - FIRE PROTECTION PUMPS

FM data sheet 3-2 - WATER TANKS FOR FIRE PROTECTION

FM data sheet 3-0 – HYDRAULICS OF FIRE PROTECTION SYSTEMS

FM data sheet 5-48 – AUTOMATIC FIRE DETECTION

FM data sheet 8-9 – STORAGE OF CLASS 1, 2, 3, 4 AND PLASTIC COMMODITIES

FM data sheet 4-5 – PORTABLE EXTINGUISHERS

FM data sheet 5-40 – FIRE ALARM SYSTEMS

FM data sheet 5-18 – PROTECTION OF ELECTRICAL EQUIPMENT

FM data sheet 7-83 – DRAINAGE AND CONTAINMENT SYSTEMS FOR IGNITABLE LIQUIDS

FM data sheet 7-88 – FLAMMABLE LIQUID STORAGE TANKS

The basic project design include :

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13003 M FF 00 LI 0100 TO SPRINKLER LIST - PROCESS OCCUPANCIES

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13003 M FF 00 LI 0150 TO SPRINKLER LIST - OTHER ACTIVITY13003 M FF 00 LI 0125 TO SPRINKLER LIST - STORAGE13003 M FF 00 PI 8020 TO SPRINKLER SYSTEM FOR MAIN BUILDING - P&ID 13003 M FF 00 PI 8010 TO SPRINKLER SYSTEM UNDERGROUND PIPE - P&ID 13003 M FF 00 PI 8001 TO SPRINKLER SYSTEM FIRE STATION - P&ID 13003 M FF 00 DS 0100 TO FIRE STATION DATA SHEET13003 M FF 00 DS 0125 TO SPRINKLER SYSTEM DATA SHEET13003 M FF 00 DS 0150 TO HYDRANTS SYSTEM DATA SHEET13003 M FF 00 DS 0175 TO Valve list13003 M FF 00 RT 1000 TO FIRE FIGHTING REPORT13003 M FF 00 BQ 0010 TO FIRE FIGHTING BILL OF QUANTITY13003 M FF 00 GA 0100 TO FIRE FIGHTING GENERAL DISTRIBUTION LAYOUT13003 M FF 11 GA 0100 TO FF BLd 11 - Ground Floor13003 M FF 11 GA 0125 TO FF BLd 11 - First Floor13003 M FF 11 GA 0150 TO FF BLd 11 - Second Floor13003 M FF 12 GA 0100 TO FF BLd 1213003 M FF 13 GA 0100 TO FF BLd 1313003 M FF 14 GA 0100 TO FF BLd 1413003 M FF 15 GA 0100 TO FF BLd 1513003 M FF 21 GA 0100 TO FF BLd 21

13003 M FF 22 GA 0100 TOEQUIPMENTS LAYOUT - BUILDING 207 - FIRE FIGHTING TANKS AND PUMP STATION

13003 M FF 22 GA 0100 TO FF BLd 2213003 M FF 23 GA 0100 TO FF BLd 2313003 M FF 24 GA 0100 TO FF BLd 2413003 M FF 31 GA 0100 TO FF BLd 31 Ground floor13003 M FF 31 GA 0125 TO FF BLd 31 First floor13003 M FF 32 GA 0100 TO FF BLd 3213003 M FF 33 GA 0100 TO FF BLd 33 Ground floor13003 M FF 33 GA 0125 TO FF BLd 33 First floor13003 E FA 00 BD 0100 TO Fire Fighting - System Architecture Block Diagram13003 E FA 11 GA 0100 TO Fire Fighting - 101 Mixing room and Raw Material Warehouse13003 E FA 12 GA 0100 TO Fire Fighting - 102 Semifinishing13003 E FA 13 GA 0100 TO Fire Fighting - 103 Tyre Building13003 E FA 14 GA 0100 TO Fire Fighting - 104 Curing Building13003 E FA 15 GA 0100 TO Fire Fighting - 105 Finishing / 106 Finished PW13003 E FA 21 GA 0100 TO Fire Fighting - 201 Electric / 202 Water / 203 Air13003 E FA 22 GA 0100 TO Fire Fighting - 207 Fire Fighting Station13003 E FA 23 GA 0100 TO Fire Fighting - 204 Boiler House13003 E FA 24 GA 0100 TO Fire Fighting - 107 Indoor Test13003 E FA 31 GA 0100 TO Fire Fighting - 901 Office13003 E FA 32 GA 0100 TO Fire Fighting - 903 Infirmary / 904 Canteen / 905 Mosque13003 E FA 33 GA 0100 TO Fire Fighting - 906 Lockers Room13003 E FA 34 GA 0100 TO Fire Fighting - 907 Entrance13003 E FA 42 GA 0100 TO Fire Fighting - 402 Flammable Storage / 403 Oil Storage

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Particularly, to provide a correct hydraulic calculation document, it is necessary, in the final

project, to elaborate the details document .

Only after FM Global approval the firefighting systems project can be considered suitable.

All the necessary details and any changes required by FM Global must be incorporated

in the final project.

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4 STRUCTURAL AND CIVIL DESIGN SPECIFICATIONS

Following general rules shall be adopted into the detail structural and civil design:

- all the main construction materials used in the factory shall be not combustible materials (insulations, cladding panels, skylight, …)

- the fire rating (R180) and the intumescent painting shall be foreseen only for the following buildings: 101 Mixing Room, 101 R.M. Warehouse, 123 Factory spare parts WH, 106 F.P. Warehouse, 402 Flammable storage, 403 Oil Storage. All the other process and civil buildings could be simply painted.

- REI 180 walls shall be foreseen between different production area (for example between 102 and 103), but not between production areas and adjacent buildings (for example between 103 and 902-C)

- in the layout must be provided an adequate distance between water reserve tanks, pump station room and protected spaces.

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5 FIRE FIGHTING SYSTEMS DESIGN

5.1 SPRINKLER SYSTEMS DESIGN

As a general primary guideline, sprinkler heads must be installed and spaced in accordance with

FM Global standards, that refer to following principal factors:

1. building height;

2. building structure;

3. slope of the roof;

4. internal areas typology;

5. Flammable liquids/gas/solids quantities stored in the different areas.

The following are the preliminary sprinkler systems design specifications, to be considered as

general references, it must be necessarily verified and justified with hydraulic calculations during

the development of fire protection specifications:

Production building

Wet sprinkler protection must be designed to provide a minimum density of 25lpm/ m 2.

For detailed features of sprinkler system types for Production Area refer to document 13003-M-

FF-00-LI-0100.

Maximum distance allowed between sprinkler heads and building ceiling is 350mm. However, it is

recommended 100÷120 mm distance installation under the ceiling.

A 1900 lpm hose allowance must be included in the hydraulic calculations, and a duration of

1,5 hour must be considered.

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W ar e h o u s e/ st o r a ge are a :

For detailed features of sprinkler system types for Production Area refer to document 13003-M-FF-

00-LI-0125.

A 950 lpm hose allowance must be included in the hydraulic calculations, and a duration of 1,5

hour must be considered.

Maximum distance allowed between sprinkler heads and building ceiling is 425 mm.

The Quick Response sprinkler protection must be extended 4,5 meters over each side

warehouse border.

Office, Laboratories, Canteen :

For detailed features of sprinkler system types for Production Area refer to document 13003-M-FF-

00-LI-0150.

A 1900lpm hose allowance must be included in the hydraulic calculations, and a duration of 1,5

hour will be considered.

Utility room/Equipment room:

For detailed features of sprinkler system types for Production Area refer to document 13003-M-FF-

00-LI-0150.

A 1900lpm hose allowance must be included in the hydraulic calculations, and a duration of 1,5

hour will be considered.

Fi r e p u mpi n g sta t ion r o om :

This area must be protected by sprinkler system, according to FM Global specific standards.

Generally, the distance between sprinkler heads and building roof ranges from 25 mm to 300 mm

from intrados roof.

A reduction distance must be considered between perimetral sprinkler heads and perimetral walls

inside the building, in compliance with FM standards.

Sprinkler equipment must be realized in order to be tested at 14 bar for 4 hours, according to FM

Global standard. Test should be conducted on graphic printer that shows time and related pressure

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value.

Fire pumps must ensure an operating constant pressure of 12 bar for sprinkler equipment.

Small pressure fluctuations must be compensated by a jockey pump.

Flushing connections should be provided and connected from all sprinkler cross main ends. The

flushing connections should consist of a nipple sized at 50 mm or larger, an isolation valve and

extend to outside directly.

To feed sprinkler systems must be provided alarm check valves that are characterized by the

following main components:

1. Water motor alarm or electrical device alarm (to generate local alarm in case of sprinkler

system activation);

2. Flow meter (for carry over the remote alarm towards the control room);

3. Drain system piping (for sprinkler system discharge).

Below is attached a typical alarm check valve diagram. It shows a typical wet system riser.

Fig.1 – Example of Wet system riser

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It is also necessary to provide a single collector, on which all alarm check valves are installed and it

must have post indicator valves to section each portion of sprinkler protection system, controlled by

each single alarm check valve (N°1 Post indicator valve for each alarm check valve and N°1 Post

indicator valve on the water supply pipe):

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Fig. 2 – Example of Alarm check valves collector

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5.2 HYDRANT SYSTEMS DESIGN

All the plant must be internal and external covered/protected with both internal hoses and external

yard hydrants, minimum diameter DN100. Hydrants must be spaced according to local standards

and current laws.

External hydrants must be UNI70 typology, internal hydrants must be UNI45 typology.

It also must be provided an external Fire Brigade pump connection.

To show equipment typologies required, some photographs are attached below:

Fig. 3 – Example of UNI70 hydrant (external hydrant)

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Fig. 4 – Example of UNI45 hydrant (internal hydrant)

Fig. 5 – Example of external Fire Brigade pump connection

Yard hydrant should be able to provide 1900 l/min flow rate at the minimum residual pressure of

1,4 bar.

Because of there isn’t an outside interruptible water source (as a drinking water pipe), it is

necessary to connect hydrants mains to fire pumps station.

5.3 WATER SUPPLY AND PUMP STATION SPECIFICATIONS

In order to feed the proposed sprinkler and hydrants systems, the new water supply must consist of a new

an external tank, with a capacity of 1500 m3, from which two FM Approved multistage diesel driven fire

pumps (100% backup), plus a jockey pump, must take suction.

Fire pumps must be designed and installed according to FM standards and it must be defined their

characteristic functional curve, with flow and pressure data.

Diesel fuel fire pump tank must be located close to the pump, in the same room.

Diesel fuel fire pump tank must be realized and kept filled up in order to ensure 8 hours of

continuous operation of the fire fighting pump.

A flow testing facility should be provided for the fire pumps. This could be on a by-pass teeing off the

discharge flowing through a FM Approved flow meter and back into the tank.

The flow meter should be able to test up to 175% of pump’s rated capacity. A control valve should not be

installed within 10 pipe diameters of the flow meter inlet or within 5 pipe diameters of the outlet.

Size test outlets so they are capable of water flow of not less than 175% of the pump’s rated

capacity.

The pressure relief valve should be placed between the pump and the pump discharge check valve so it can

be readily removed for repairs without disturbing the piping.

The water reserve duration must be 120 min.

Particularly, it is suggests the external tank solution, due to the presence of a superficial

groundwater that complicates underground tank installation.

Below is shown a typical external tank with circular structure, FM Global approved and in

accordance with NFPA regulations:

Fig. 6–Fire fighting tank

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The external tank must be installed on suitable reinforced cement wrought and the tank must be

tested and approved by FM Global, in accordance with NFPA standards.

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5.4 UNDERGROUND AND ABOVEGROUND MAINS

An underground main pipe must be provided to feed fire protection systems. The same pipe must be provided, for sprinkler system and for hydrant system:

Sprinkler system, UNI70 and UNI45 hydrants system: one underground main, made by

HDPE pipe, NP16 bar, external diameter 315 mm, looped around the plant;

The control valves must be the following:

OUTSIDE SCREW AND GATE VALVE type for above ground pipes:

Fig. 7– Example of outside screw and gate valve

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Other general information:

Rubber flexible connection should not be installed on the fire protection piping and the fire

pump connections;

Inspector’s Test Connectors should be provided and connected from the most remote branch

line ends and should be directly extended to an open area outdoor without any “tundish” so

Carbon steel (black and galvanized) pipes thicknesses must be in accordance with FM DS

2-0, with minimum thickness 3,25 mm, for threaded joints, and 3,4 mm for cut-grooved joints.

Sub-horizontal trend pipes must have a minimum slope of 2 mm per meter towards drains system.

Branch lines, with a diameter larger than 2”, shall be connected by flexible joints, like Victaulic joints,

at least one every 6 meters.

Fig. 8 – Example of flexible joint

Pipes with diameter ≤ 2” shall be connected by joint screw and

sleeve. Where a pipe passes through a wall, it is necessary to provide

boat.

About the br anch line p i ping suppor t s , th ey must be in accordance with FM Glo b al s tandards a nd t he

m a x i m um d i stance between two co n secutive su p ports is 3,6 mt.

The maximum horizontal distance between supports and sprinkler heads is 0,3 mt.

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A typical FM approved support is the U-bolt typology support, used for main pipes (diameter ≥ 2”):

Fig. 9 – Example of U-Bolt support

Another typical FM approved support is the hanger typology support, used for smaller pipes (diameter <2”):

Fig. 10 – Example of hanger typology support

Pipes must be coated with a first rust proof paint layer (thickness 30 microns) and with two second enamel red colour layers RAL 3000 (thickness 25 microns per layer).

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5.5 ALARMS SIGNALS AND MANAGEMENT

All signals coming from firefighting systems must be relayed to a constantly attended location.

Particularly, signals of sprinkler water flow and fire pump start/stop, auto/manual and fail to start

should be sent to a constantly attended location.

Particularly, it must be provided an analogical detection/alarm central, that is connected with one or

more loops, in order to receive and handle the driving signals of sprinkler systems and smoke

detection devices and to transmit signals to the remote alarm monitoring station.

Finally, it must be provided also analogical alarm button and optical/acoustic alarm panel to

generate and display fire alarms.

Below are attached a photographs of these equipment:

Fig. 21 – Example of analogical alarm button

Fig. 22 – Example of analogical alarm button

The electrical cables of optical-acoustic panels, sprinkler flow switch, snooze and interlocks must be

realized with multi-type fire-resistant type FTG100M1 LSZH 2x2, 5 mm2.

The detection loop cables must be realized with multi-type fire-resistant type FTG100M1 LSZH , version 2x0,75.

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5.6 Inert Gas Fire Suppression System

The server room in building 902-C, shall be equipped with an Inert Gas Fire Suppression System. The

system typically consists of the agent, agent storage containers, agent release valves, fire detectors,

fire detection system (wiring control panel, actuation signaling), agent delivery piping, agent

dispersion nozzles, warnings and alarms (to avoid suffocation). These Agents are governed by the

NFPA Standard for Clean Agent Fire Extinguishing Systems - NFPA 2001 in the USA, or analogue in

Indonesia.

Fire suppression systems for server rooms and data centers are essential to the server room itself. A

fire suppression system will automatically extinguish a fire without the need of human intervention.

Fire suppression systems for data centers must be suitable for clean air environments, as server

rooms and data centers are mostly occupied by personnel.

This method is to reduce the oxygen level to below 15%. By reducing oxygen to this level it will

suppress a fire. The design must also consider the safety of personnel and keep oxygen levels to

above 12%, this will be sufficient to maintain life within an oxygen depleted environment.

Inert gas fire suppression systems will discharge its payload within 1 - 2 minutes

Will generally have more cylinders of chemical gases

Work with higher pressures, 200 Bar or 300 Bar

Will require Pressure relief venting

The designs standards for Fire suppression systems for server rooms and data centers are carried

out with strict guidelines, as the fire suppression agents used can be dangerous if not designed

correctly.

The design of the system must protects against accidental actuation due to any small leak. As a

general rule, extinguishing concentration is achieved when oxygen contents in the air is reduced from

its usual level of 20,9% to values lower than 15% depending on the combustible products.

6 FLAMMABLE LIQUID STORAGE

For flammable liquid storage the principal requirements are the following:

Mechanical low level ventilation; the mechanical ventilation project must be performed

following space classification of electrical system typology installed (ATEX);

Rated electrical equipment which should be suitable for hazardous environment;

Drainage and containment to prevent the flowing liquid into the area.

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7 SMOKE DETECTION SYSTEMS

Smoke and heat detection systems should be provided for all Electrical Rooms, Server Rooms,

office.

Air analysis unit for ceiling and floating floor detection systems should be provided for all

offices.

Transmitters infrared smoke detector and heat detectors should be provided for production

departments.

All detection systems shall be in accordance with local and current laws, including inside raised

floor area and other places where necessary. The signals should be transferred to a constantly

attended location, which could be the fire control center located in the guard house.

Detectors must be in accordance with EN54-7, with protection degree IP43.

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8 HYDRAULIC CALCULATIONS

On the basis of the above design specifications, a series of hydraulic calculations must be

provided. More in detail one calculation must be provided for each protected area.

In accordance with hydraulic calculation results, it will result specifications for fire pumps, with

a sufficient safety margin.

Considering a 120 minutes duration of the water reserve tank, it will result the water amount

needed to feed sprinkler system and hydrants system.

9 OTHER TOPICS TO IMPROVE

1. Fire and security signals;

2. Safety place points (emergency evacuation);

3. Valve padlocking and numbering;

4. Earthquake equipment and devices;

5. Fire extinguishers placement in the plant.