CO2 Flooding System (Fixed Fire Fighting System)

Carbon dioxide is the fire extinguising medium used in CO2 flooding system. It is an effective
fire suppression agent applicable to a wide range of fire hazards. It has a high rate of
expansion which allows it to work fast. When applied to a fire, CO2 provides a heavy blanket
of gas that reduces the oxygen level to a point where combustion cannot occur. Since carbon
dioxide is a gas, there is no clean up associated with a system discharge. CO2, a compound of
carbon and oxygen, is a colourless gas which cause coughing to occur when inhaled. At higher
concentrations it is acutely toxic. Low and high pressure CO2 is used for the fire protection of
machinery spaces, pump rooms, cargo holds, paint stores and galley exhaust ventilation ducts
on board ships.

There are several advantages for the CO2 as a fire fighting medium.

➢ Density is 1.5 times higher than air. So CO2 settles down and displaces air.
➢ It can be easily liquefied and bottled.
➢ 20% – 30% CO2 concentration extinguishes fire by smothering
➢ Non-corrosive
➢ Non- conductor of electricity
➢ No residues left after application
➢ No deterioration with age
➢ Similarly there are some disadvantages also, such as:
➢ CO2 is highly asphyxiating. 9% concentration causes unconsciousness within minutes
➢ Very little cooling effect. So there is danger of re-ignition.
➢ When discharged, solid CO2 particles present and generate sufficient static electricity
to produce spark.

Explanation of CO2 Flooding System

As mentioned earlier CO2 flooding system floods the protected space under fire with carbon
dioxide, which displaces air, thereby removing one leg of fire triangle for the extinction of fire.
CO2 flooding system consist of main CO2 bottles, common manifold, master valve or
distribution valve and distribution pipe lines with nozzles as shown in the figure below.

Main CO2 bottles contain carbon dioxide in liquid state with a pressure of 56 bar at 20 degree
Celsius. Pressure of CO2 at 25 and 30 degree Celsius are 64 bar and 71 bar respectively. So it is
important to keep the temperature of CO2 bottles low for limiting the pressure inside bottles.
CO2 from the main bottle is released by a ‘CO2 release cabinet’ as shown in the figure. As
soon as the release cabinet door is opened, a micro switch is activated. The micro switch will
ensure the activation of CO2 warning alarms and ventilation shut off. CO2 release cabinet or
release box consist of two pilot CO2 cylinders or bottles containing CO2 gas inside. The
pressure of CO2 inside these pilot bottles is same as that of main CO2 bottles. Only quantity of
gas is different. For releasing CO2 to the protected space, one of the pilot bottle valve is
opened. Now CO2 reaches two valves marked 1 and 2. First valve 1 is to be opened. Then CO2
passes through a non return valve and opens pneumatically operated master valve. Now
master valve is opened. Next, open valve 2 in the release cabinet, which supply CO2 to main
CO2 bottle head assembly through a non return valve and ‘time delay unit’. Function of the
time delay unit is explained below. Head assembly consist of a pressure operated cylinder
valve. This pressure operated cylinder valve prevents CO2 from bottle coming to the common
manifold. As CO2 reaches the head assembly from pilot bottle, pneumatic actuator in the head
moves and opens the pressure operated cylinder valve. Then CO2 from main bottle escapes to
the common manifold via non return valve as shown. Each of the main CO2 cylinder have a
head assembly and non return valve. The pilot CO2 line is connected to all these heads. All the
CO2 from the main bottles now release to common manifold. Since the master valve is already
open before, CO2 from manifold is released to the protected space through distribution pipe
lines and nozzles.

As you can see in the diagram, there are two CO2 release cabinets. One is local release
cabinet and is located in the CO2 room itself. One more remote release cabinet is used, which
is located in a remote place such as fire control station. This facilitates operation of CO2
flooding system from a remote place other than CO2 room. Both release cabinets are
connected in parallel and non-return valves fitted in the lines prevent back flow of CO2. Also
two pilot CO2 bottles are placed in the release cabinet. Only one is sufficient for the operation
of both master valve and CO2 bottle head assembly.

CO2 flooding system explained here protects only a single space. There are systems which can
protect multiple spaces such as engine room and pump room together. In that case separate
release cabinets will be there for engine room and pump room. Main CO2 bottles are shared
for engine room and pump room according to the volume of the spaces.

Time Delay Unit in CO2 Flooding System

CO2 from the pilot bottles in release cabinet reaches main CO2 bottle head assembly through
a time delay unit. Function of this time delay unit is to delay the supply of CO2 to the head
assembly for 60 – 90 seconds. In other words, when valve 2 in the release cabinet is opened,
CO2 reaches only after 60 to 90 seconds to the head assembly. Reasons for providing such a s
delay in CO2 flooding system are given below.
1. As soon as CO2 release cabinet opens, alarm is sounded in the protected space. A time
delay of 60 to 90 seconds gives sufficient time for any personnel in the protected space
to escape, even after the operation of both valves in the release cabinet.
2. If CO2 is released from main bottles to the common manifold before opening master
valve, there may be difficulty in opening master valve because of the bulk CO2
pressure acting on it. Because of the time delay, positive opening of the master valve is
ensured before releasing CO2.
What are the requirements of CO2 Room
In CO2 flooding system, carbon dioxide bottles are placed in a separate room called CO2 room.
The requirements for location, accessibility, use and ventilation of CO2 storage spaces as per
IMO are:
➢ Spaces for storage of cylinders or tanks for extinguishing gas should not be used for
other purposes.
➢ These spaces should not be located in front of the forward collision bulkhead.
➢ Access to these spaces should be possible from the open deck.
➢ Spaces situated below the deck should be directly accessible by a stairway or ladder
from the open deck.
➢ The space should be located no more than one deck below the open deck.
➢ Spaces where entrance from the open deck is not provided or which are located below
deck are to be fitted with mechanical ventilation.
➢ The exhaust duct (suction) should be lead to the bottom of the space.
➢ Such spaces should be ventilated with at least 6 air changes per hour.
Requirements of CO2 Flooding System
➢ Discharge requirement is, at least 50% of CO2 discharge to be carried out in 1 minute
and at least 85% discharge in 2 minutes.
➢ Safety procedures must be there against unauthorized use of the system.
➢ Machinery space to be fitted with audio-visual alarm and ventilation blower trip.
 ➢ Alarm must trigger well before operation of CO2 flooding system.
➢ Permanent piping arrangements should be made.
➢ Manifold, distribution piping to be pressure tested. See Pressure Testing of CO2
Flooding System below.
➢ Diameter of associated pipe lines in the system should not be less than 20 mm.
➢ Copper and flexible pipes are allowed between CO2 cylinder and common manifold.
➢ Distribution pipes to cargo spaces should not pass through engine room.
➢ All stop valves to be checked every month to ensure their working and position.
➢ The CO2 flooding system installation to be checked monthly for any leakages.
➢ All control valves to be tested annually.
Maintenance of CO2 Flooding System
Fixed carbon dioxide fire extinguishing systems should be kept in good working order and
readily available for immediate use. Maintenance and inspections should be carried out in
accordance with the ship’s maintenance plan having due regard to ensuring the reliability of
the system. The on board maintenance plan should be included in the ship’s safety
management system and should be based on the system manufacturer’s recommendations.
Monthly
Alarms, Machinery trips, Door alarm, Quick closing valves, Flaps, Skylights, Ventilation fan trips
to be tested.
Yearly
General inspection of the installation, pipe lines to be checked.
2 Yearly
1+
1. Verify CO2 contents by mechanical advantage lever, ultrasonic liquid level
measurement or radioactive liquid level measurement. Equipment for measuring CO2
content must be available on board ships. A maximum reduction of 5% in CO2 content
may be allowed provided total CO2 quantity on board is not less than the required
amount.
2. Blow through the system with 6-7 bar air with plastic air bags at the nozzle ends.
5 Yearly
1. 1+2+
2. The servo cylinders and any remote controlled stop valves to be tested by opening one
pilot cylinder. The main CO2 bottles must be uncoupled for this purpose.
3. Spring loaded relief valves to be checked and pressure tested at 180 bar.
4. Checking of HP alarms which operate with gas pressure.
5. Section of CO2 which can be shut off must be tested with air at 25 bar.
10 Yearly
 1. 1+2+5+
2. CO2 bottles to be inspected internally. Siphon tube or dip tube to be checked.
Cylinders to be pressure tested at 250 bar. If permanent change in volume is observed,
those cylinders to be discarded. After 20 years of installation of CO2 flooding system,
these tests to be carried out every 5 years thereafter.
15 yearly and 5 year thereafter
1. 1+5+
2. Pressure test HP pipes, stop valves to engine room, pump room, purifier room,etc. at
190 bar (hydraulic), medium pressure pipes at 80 bar (hydraulic) and low pressure
pipes at 7 bar air.
3. After hydraulic pressure testing, lines to be blown through by dry air.
Procedure of Releasing CO2 to the Engine Room on Ships
1. Muster and take head count.
2. Master will take decision, depending upon the situation and as per the company policy.
3. If total CO2 flooding of engine room is to be done, master will consult with chief
engineer.
4. Nearest coast guard to be informed as soon as possible.
5. Ensure proper sealing of the engine room.
6. Make sure emergency generator is running and on load. Power is required for running
emergency fire pump for boundary cooling.
7. All access doors, vent flaps, blower flaps, skylights, hatches, fire flaps, to be closed.
8. Quick closing valves to be closed.
9. Emergency stops for lube oil pumps, fuel oil pumps to be operated.
10. All machinery in engine room to be stopped.
11. Ensure all personnel vacated engine room.
12. CO2 must be released by competent engineer.
13. Break the glass and take out key for CO2 release cabinet from key box. Using local CO2
release cabinet is preferred.
14. Open the release cabinet. Audio visual alarms will sound and ventilation blower trips
will activate.
15. In the CO2 release cabinet, open pilot cylinder valve first. Now open valve 1 for master
valve first. Then open valve 2 for CO2 releasing mechanism. Co2 will be released after
60-90 seconds of time delay.
16. Now the system pressure can be checked from the pressure gauge on the manifold.
17. If CO2 is not released, then follow emergency releasing procedure. Open master valve
manually and open each CO2 main bottle by manual actuation lever.
Important Notes on CO2 Flooding System
CO2 flooding is the final course of action, used only when all else has failed. Proper sealing of
the engine room is essential for effective extinction of fire. There were incidents like CO2 is
released, effective smothering did not occur due to improper sealing of engine room and fire
remained unextinguished.
To obtain a total flooding of engine room, about 35% by volume of CO2 is required in 2
minutes. This will reduce the oxygen content of the air in engine room to less than 15% to
extinguish the fire. At this CO2 concentration human life cannot be supported.
Typically it takes about 15-20 seconds after release of CO2 before the concentration in engine
room reaches a dangerous level.
Safety Precautions After CO2 Release
After CO2 flooding system is operated efficiently, engine room fire will extinguish by
smothering action. But before engine room entry is made or space ventilated, it is
recommended to obtain expert advice from shore. Nearest coast guard can be contacted for
getting assistance for the same.
1. The first question is, how to make sure that CO2 is actually released after the operation
of CO2 flooding system. When CO2 is released there will be a loud noise of gas
escaping to the protected space. CO2 bottles can be felt cold after releasing. Visual
inspection of the operation of, pressure operated cylinder valves also can be carried
out.
2. CO2 has very little cooling effect. So there is a danger of re-ignition of fire when engine
room is ventilated immediately. Keep the boundary cooling running to reduce the
temperature of the engine room.
3. Ventilation of engine room should not be started until it has been definitely
established that the fire has been extinguished completely, which will take several
hours.
4. Engine room to be sufficiently ventilated before entering.
5. Entry to be carried out by trained personnel wearing breathing apparatus.
6. Even after fire has been extinguished completely, never bring bare flame such as
candle light or lighted cigarette into the burnt room, other wise fire may break out
again due to explosion of combustible gases, if any.
7. In order to allow persons to get away quickly and safely in case of fire, entrances and
exits shall be always kept clear.
8. Back up team or support team to be ready in case any difficulties happens in side.
9. An attendant should be instructed to remain at the entrance of the engine room.
10. An agreed and tested system of communication to be established between attendant
and team inside engine room.
11. In case any emergency occur to the team inside engine room, the attendant is not
supposed to enter inside before the help has arrived.
12. In the event of ventilation system fails, the personnel in the space should leave
immediately.