CO2 System

Total flooding.
 CO2 Cylinders

• The cylinders are 67.5-litre steel

cylinders filled with 45 kg of
CO2.
• (alternatively as 80-litre steel GAS

cylinders filled with 53.6 kg of

CO2.)
• The Head assembly valve has a
built-in bursting disc, activated at CO2 Liquid
a nominal pressure of 190 bar.
• Liquid Siphon Tube.
• Top portion of the cylinder is
having CO2 Gas
2
HIMT
• Head assembly mainly consist of CO2 Main Bottle Head Assembly
a cylinder valve, which is Lever Inserted
operated by a pneumatic here
actuator and linkages as shown
in the figure below.
• CO2 from the release cabinet
reaches the pneumatic actuator
through time delay unit and
actuator operates the cylinder
valve to release CO2 from main
bottles to the common manifold.
• The pressure operated cylinder
valve shown in the figure can
also be manually operated by Lever
use of a lever inserted into the
top of the valve.
• Free space above the
valve should be minimum
200 mm.
• The closing nut is to be
screwed tight to the valve
outlet during transport
and storing of cylinders
with valve fitted.
• The cylinder valve is
always supplied with a
cotter pin or split pin as
shown for securing
cylinder after filling and
during any maintenance
on the CO2 flooding
system.
 CO2 High Pressure Fire Extinguishing System

• Suitable for extinguishing fire in spaces like Engine rooms, Auxiliary

engine rooms, cargo holds, etc.
• Extinguish the fire within a short time and leave no residue after
extinguishing: machinery shut-down time after a fire will be reduced
to a minimum
• Suitable for extinguishing fires in combustible liquids, gases and
electrical equipment.
• Installed as a total flooding central bank system inclusive of a number
of distributions
• Normally installed with pneumatic release, but can also be supplied
with mechanical, electrical, and manual release

6
HIMT
CO2 system layout.
 CO2 Room.

• The cylinders are normally stored in a separate,

well-ventilated and insulated room, where the
temperature is kept between 0° and 40°C.
• CO2 is a non-toxic gas, but may displace the
oxygen present in the space.
• It has a critical temperature of 31.350 C, heated
above will expand to gas at .56 m3 (ie 1 kg
Liquefied gas = .56 m3 gas volume / 1ltr
• Main CO2 bottles contain carbon dioxide in
liquid state with a pressure of 56 bar at 20
degree Celsius.
• Pressure of CO2 at 25 deg C is 64 bar and
• Pressure of CO2 at 30 degree C is 71 bar.
• So it is important to keep the temperature of
CO2 bottles low for limiting the pressure
inside bottles.
KEY
CO2 Bank Release from two
different Locations.
1. CO2 Room.
2. Fire Control Station
TIME
I
Delay Fire Control Station
 System Arrangement
• CO2 system consists of one or more pressure cylinders containing
the extinguishing agent CO2.
• The cylinders are connected via a common manifold.
• CO2 cylinders connected in gangs operated pneumatically from
one or more release cabinets equipped with CO2 gas cylinders.
• The release cabinets are equipped with pilot valves for use in
opening cylinders and distribution valves by pipe connections.
• For pneumatic operation, the built-in actuator is used for each
cylinder head assembly valve.
• These are connected to the other cylinder valves in the group via
series-connected, flexible high-pressure hoses with non-return
valves.

13
HIMT
CO2 Release system
 By-pass

CO2 Bottle
Head
Assembly

15
HIMT
• 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 in Engine
Room.
• CO2 release cabinet or release box consist of two
pilot CO2 cylinders containing CO2 gas inside.
• The pressure of CO2 inside these pilot bottles is 5
bar.
• Only one control cylinder at a time is used. Another
one is stand-by.
• 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.
 Time delay Unit Reasons…..
• 1. As soon as CO2 release cabinet opens, alarm is sounded in the
protected space. A time delay of 60 to 90 seconds give 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.
• 3. Regulation per International Code for Fire Safety System (FSS
Code) 2.1.3.2 says, “The pre-discharge alarm can be automatically
activated (e. g. by opening the release cabinet door). The alarm
shall operate for the length of time needed to evacuate the space,
but in no case less than 20 seconds before the medium is
released.”
• electrical type, which has an AC 220 V power supply, a pressure switch,
timer and a solenoid valve as shown in the figure below.
• Power source is always available for the unit. Solenoid valve is
normally in closed position.
• When CO2 from pilot cylinder (CO2 release cabinet) reaches the
time delay unit, the pressure acts on the pressure switch.
• This closes the pressure switch.
• But the timer allows power supply to the solenoid only after 60-90
seconds, the timing can be adjusted as required.
• As soon as the specified time is reached, solenoid becomes
energize and the solenoid valve will open.
• This allow passage of CO2 to the pressure operated cylinder valve
of main bottle.
• Normally a by pass valve is also fitted across this time delay unit
which can be used in case the unit goes defective.
 Time delay unit
pneumatic

• This type of time delay unit uses an empty bottle fitted

just before the head assembly.
• This empty bottle fills first before supplying pressurised
CO2 to the head assembly.
• This is more reliable since there is no electrical
components involved.
• Figure shows two time delay units, one for engine room
and the other for other compartment.
• Time delay unit head assembly have in-built nozzle.
Time delay is set and checked in the Factory.
• Time required to fill up the bottle depends on the
nozzle hole diameter.
Bursting Disc.

Safety valve.
Bursting Disc
 Busting Disc
• Bursting Disc in CO2 Flooding System
• The pressure of CO2 inside the bottle depends on the temperature
of the surroundings.
• As temperature increases, pressure also increases.
• Therefore to safeguard against abnormally high pressures inside the
bottle, a bursting disc is provided on the head assembly as shown in
the figure .
• When the CO2 pressure inside the bottle increases to about 200 bar,
bursting disc burst and releases CO2 to the CO2 room.
• Pressure inside the bottle build up to such a high value means there
is a fire inside CO2 room.
• Here, CO2 released from the bottle itself extinguishes fire inside the
room.
 Relief Valve.
• Why Relief Valve is Required?
• There is a relief valve fitted in the manifold of CO2
flooding system.
• Function of the relief valve is to release the CO2
pressure in the manifold to the atmosphere outside
CO2 room.
• Such a situation arises when CO2 get released from
the bottle and master valve is still closed.
• Set pressure of relief valve is about 180 bar.
• Again, set pressure varies with the system design
and regulations.
• A relief valve is required for two purposes:

• 1. If the pressure of fluid in a pipe line increases beyond the designed

working pressure, there must be a pressure relief mechanism for bringing
down the pressure to safe guard the system.
• In the case of CO2 flooding system, CO2 will accumulate in the manifold
when it is released from the bottle and master valve is closed.
• Pressure of CO2 is 55 bar at 20 degree Celsius.
• As CO2 takes temperature from surroundings, its pressure also increases
to dangerous levels.
• Since these pipes are pressure tested to 190 bar only, a relief valve is
necessary in the manifold.
• 2. Any pressure accumulate in the manifold may release other CO2
bottles which are intact, if the non return valve between bottle and
manifold is damaged.
• What are the requirements of 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.
• The space should be located no more than one deck below the
open deck.
• 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
• 1. Discharge requirement is, at least 50% of CO2 discharge to be carried
out in 1 minute and at least 85% discharge in 2 minutes.
• 2. Capacity of CO2 in the system to be,
• a.) 30% of the gross volume of the largest protected cargo space,
• b.) 40% of the gross volume of machinery space excluding engine casings,
• c.) 35% of the gross volume of machinery space including engine casings
for vessels GT < 20000.
• Total amount of CO2 cylinders depends on the highest gross volume
out of above a, b, c in a particular ship.
• 3. Safety procedures must be there against unauthorized use of the
system.
• 4. Machinery space to be fitted with audio-visual alarm and ventilation
blower trip.
• 5. Alarm must trigger well before operation of CO2 flooding system.
• 6. Permanent piping arrangements should be made.
 CO2 Flooding Requirement…….

• 7. Manifold, distribution piping to be pressure tested. See Pressure

Testing of CO2 Flooding System below.
• 8. Diameter of associated pipe lines in the system should not be less
than 20 mm.
• 9. Copper and flexible pipes are allowed between CO2 cylinder and
common manifold.
• 10. Distribution pipes to cargo spaces should not pass through engine
room.
• 11. All stop valves to be checked every month to ensure their working
and position.
• 12. The CO2 flooding system installation to be checked monthly for any
leakages.
• 13. All control valves to be tested annually.
 Calculation of CO2 Required
 Quantity of free carbon dioxide calculation at 0.56 m3/ kg
 Mixing ratio of CO2 based on the volume of protected spaces to be as follows:
a) Gross volume of engine room space including casing = 35%

a) Gross volume of engine room space excluding casing = 40%

a) Gross volume of purifier room space = 40%

 Quantity of CO2 in kg = (GROSS VOLUME x MIXING RATIO) / 0.56

QUANTITY OF
GROSS MOLUME QUANTITY OF 45 KG
NO. NAME OF SPACE (M3) CO2 (KG) CYLINDER
ENG ROOM SPACE
1 INCL. CASING 7324 4577.5 102
ENG ROOM SPACE
2 EXCL. CASING 6856 4897.14 109
PURIFIER ROOM
3 SPACE 132 94.2 3

Therefore required quantity of 45 kg CO2 cylinder for engine room = 109

Note: The air reservoir in engine room space is not included in the above
calculation since the outlet of safety valve shall be led to atmosphere outside
engine room.
Pressure Testing of CO2 Flooding System

Pipe Section Area Material Test

Branch Pipe to Galvanized Seamless
Low Pressure Section Nozzles Manganese Steel 7 Bar Air Blowing Test

Medium Pressure Master Valve to Main Galvanized Seamless

Section Pipe Branches Manganese Steel 80 Bar Pressure Test
CO2 Cylinder to Galvanized Seamless
High Pressure Section Master Valve Manganese Steel 190 Bar Pressure Test

Pilot Control Line Control Lines Copper Tube 58 Bar Pressure Test
 Maintenance of CO2 Flooding System

• 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
• Verify CO2 contents by: -
• a). weighing each cylinder,
• b). ultrasonic liquid level measurement or
• 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.
• Blow through the system with 6-7 bar air with plastic air
bags at the nozzle ends.
• 5 Yearly
• 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.
• Spring loaded relief valves to be checked and
pressure tested at 180 bar.
• Checking of HP alarms which operate with gas
pressure.
• Section of CO2 which can be shut off must be tested
with air at 25 bar.
• 10 Yearly
• 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
• 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.
• 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. (Chief Engineer to decide depending up on situation)
• 3. If total CO2 flooding of engine room is to be done, master will consult with chief
engineer. (as per Company policy)
• 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. (Fuel Tanks)
• 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.