Eisenhower Johnson Memorial Tunnel (EJMT)

Fixed Fire Suppression System Preliminary Design:

Task 3 – Preliminary Design of Retrofitting a Water Mist System at
EJMT

Prepared for the

Colorado Department of Transportation

August 2012
Revised October 9, 2012
Some of the information in this report has been provided to HMM, Parsons and CDOT in confidence and
should not be disseminated.

Prepared by

Hatch Mott MacDonald

475 Park Avenue South, 10th Floor

New York, New York 10016-6901

And

Parsons

1700 Broadway, Suite 900

Denver, CO 80290

10/9/2012
This page is left intentionally blank.

10/9/2012
 TABLE OF CONTENTS

1.0 I ntr oduction ....................................................................................................... 1

2.0 Pr eliminar y Design of R etr ofitting a W ater M ist F F F S at E J M T ............... 1
2.1 Design Objectives, Standards & Design Criteria ...................................................................... 1
2.2 Design Concept, Calculation Criteria and System Design Calculations ................................... 2
2.2.1 Design concept of a water mist system...................................................................... 2
2.2.2 Calculation criteria and system design calculations for EJMT .................................. 3
2.3 Main Components and Layout of a Water Mist System for EJMT ........................................... 6
2.3.1 Nozzles and nozzle layout ......................................................................................... 6
2.3.2 Main pipe and section pipes with nozzles ................................................................. 6
2.3.3 Section valves ............................................................................................................ 9
2.3.4 Pump stations ............................................................................................................. 9
2.3.5 Water reservoirs ....................................................................................................... 10
2.3.6 Drainage requirement .............................................................................................. 11
2.3.7 Activation (fire detection) and system control ........................................................ 11
2.3.8 Filtration, water quality and frost protection ........................................................... 11
2.4 Cost Estimate........................................................................................................................... 12
2.4.1 AQUASYS system .................................................................................................. 12
2.4.2 FOGTEC system...................................................................................................... 14
2.4.3 HI-FOG system........................................................................................................ 15
2.5 Maintenance ............................................................................................................................ 16

Appendix A: Preliminary Design Drawings of a Water Mist System for EJMT: AQUASYS System
Appendix B: Preliminary Design Drawings of a Water Mist System for EJMT: FOGTEC System
Appendix C: Preliminary Design Drawings of a Water Mist System for EJMT: HI-FOG System
Appendix D: Discussion of Fire Suppression Methods and Recent Data
Appendix E: Examples of Water Mist Systems Installed in Road Tunnels (Updated Data as of Jan 2012)

i 10/9/2012
ii
 1.0 I ntr oduction
Hatch Mott MacDonald (HMM) and Parsons have been engaged by the Colorado Department of
Transportation (CDOT) to undertake a water mist fixed firefighting system (WM-FFFS)
preliminary design for EJMT. The scope of this project includes the following:
• Task 1 – Further evaluation of the WM-FFFS based on the full scale tunnel fire
tests
• Task 2 - CFD model studies to examine system performance and gain more
insight of the effects of the water mist system on tunnel fires
• Task 3 – Preliminary design for retrofitting a WM-FFFS at EJMT
• Task 4 – Verification of CFD ventilation model via field tests in EJMT

This report documents the preliminary design for retrofitting a water mist fixed firefighting
system at EJMT. An additional work item, which is the result of part of the rearrangement of the
scope of Task 3, a white paper showing the logic behind the decision on the use of water sprinkler
system in the tunnels of Alaskan Way Viaduct Project and some of the recent data on WM-FFFS
in world’s road tunnels, is also given in Appendices D and E.

2.0 Pr eliminar y Design of R etr ofitting a W ater M ist F F F S at E J M T

2.1 Design Objectives, Standar ds & Design C r iter ia
The design objectives of the proposed water mist FFFS system is the following:
• Improve the self-rescue conditions,
• Improve access and operating conditions of fire and rescue,
• Prevention of fire spread from one vehicle to another,
• Limit structural damage to the tunnels.

The water mist system will be designed in accordance with UPTUN WP2 D251–“Engineering
guidance for water based fire fighting systems” [3], NFPA 750 [5], and NFPA 502 [2].

Practical design criteria for the water mist system are the following:
• The fire load with a potential HRR up to approximately 200 MW (for both pool fires and
solid fuel fires),
• Fire should not spread from the incident vehicle to other vehicles at a distance of 5 m (16
ft) downstream,
• The Fire Fighters should be able to get within at least 5 m (16 ft) of the fire from the
upstream direction and access the area in the tunnel 20 m (66 ft) downstream,
• At 40 m (131 ft) downstream there should be at least 15% oxygen and a maximum of 5%
CO2.
 2.2 Design C oncept, C alculation C r iter ia and System Design C alculations
2.2.1 Design concept of a water mist system

The design concept of the proposed water mist system for EJMT is based on the test results from
several research projects, and many other accepted full scale fire tests using water mist system
technology (see Task 1 report of this project). This preliminary design has been in accordance
with UPTUN WP2 D251, NFPA 502 and NFPA 750.

The main components of water mist systems in tunnels are illustrated in Figure 2-1. The wet main
pipe (blue color) comes from the pump station and is pre-pressurized with low-pressure (~10 bar
or 145 psi) water to ensure that the WFS is operating in the relevant zones not later than 60 sec.
after activation. The section valve is the border between the wet main pipes and the dry section
pipes. The section pipes connect all nozzles in every section together. In the case of opening the
section valve, water will be supplied to every nozzle in this section. Normally an external linear
heat detection system is installed to the tunnels to trigger the fire fighting system and also indicate
the location of fire to the control system that opens the section valves. Alternatively, a triggering
message can come through a video based incident detection or fire detection system or by the
operator.

Figure 2-1: Layout of a water mist system

The water mist system is designed to cover the roadway area of the tunnels using nozzles
installed at a regular spacing. There will be 3 ~ 4 longitudinal nozzle rows depending on the
tunnel geometry. The tunnel is divided into zones of length 25 m (82 ft) to 30 m (98 ft), with
every zone having identical length and nozzle lay-out. Three zones will be activated in case of
fire by opening the section valves of fire zone sections (fire incident zone and two adjacent
zones). The pump system will start simultaneously.

2
 2.2.2 C alculation cr iter ia and system design calculations for E J M T
The calculation criteria for the system design for EJMT are based on manufactures’ operational
parameters obtained from the full scale fire tests.

Task 1 of this project concluded that there are significant differences in the operational
parameters for different supplier’s systems (AQUASYS, FOGTEC, HI-FOG) such as operating
pressure, water droplet sizes and water flow rate density. Since the conclusions of Task 1 are not
absolute in terms of a particular system and its ability to protect for certain types of fire, three
system designs by AQUASYS, FOGTEC, HI-FOG are provided respectively in the following
sections. Note that among these three system designs,
• AQUASYS system has been designed and tested for 200MW solid fuel and pool fire
scenarios,
• FOGTEC system has been designed based on HGV risk scenario (180 MW large solid
fuel fires) and its system design may need to be modified to combat large pool fire
scenarios,
• HI-FOG system has been designed and tested for 100 MW solid fuel fires (large vehicle
fire scenarios) and the design was claimed (by the supplier) to be adequate for large pool
fire scenarios based on simulation results.

Table 2-1 shows the design calculation criteria of AQUASYS system, FOGTEC system and HI-
FOG system established by full scale tunnel fire tests.

Table 2-1: Design Calculation Criteria for Three Water Mist Systems (AQUAYS,
FOGTEC, HI-FOG)

SUPPLIERS AQUASYS FOGTEC HI-FOG

DKIT 38/0-6.9-xL, Not specified by the
4S 1MD 6MD 1000;
Nozzle, K factor proprietary supplier, proprietary 0.5
K=5.5 lpm/bar
information information
4.17 m
2m 3.42 m
Spacing between nozzles in (13.68 ft)
(6.56 ft) (13.12 ft)
a row (longitudinal)
4m 3.56 m 3.35 m
Distance between rows
(13.12 ft) (11.68 ft) (11.0 ft)
4m ~4.7 m (15.4 ft) ~4.7 m (15.4 ft)
Nozzle distance above floor
(13.12 ft) at tunnel ceiling at tunnel ceiling
Operating (minimum) 35 bar 50 bar 80 bar
pressure at nozzles (507.6 psi) (725 psi) (1160 psi)
30 m 25 m 27.44 m
Zone length
(98.4 ft) (82 ft) (90 ft)
Nominal water flux density,
3 0.9 0.5 0.8
L/(min. m )
Nominal water flow rate,
2 4.7 2.25 4
L/(min. m )
Operation time of water
60 60 60
mist system (min)

The pipe work shall be dimensioned to ensure that at least the minimum pressure tested in the
relevant full size fire tests is achieved at all nozzles of the activated sections in any part of the
tunnel. The maximum allowable pressure loss shall be within the limits given by the maximum
and minimum tested pressure. Note that some suppliers are withholding nozzle characteristics
information for proprietary reasons, therefore detailed hydraulic calculation were done by the
suppliers and not presented in this report. Nevertheless the following presents a brief summary
of some hydraulic calculation procedures for a water mist system:

1. Flow rate through a single nozzle qi

Where Pi, K are the nozzle working pressure and nozzle K factor respectively

2. Total flow rate of the system

Where n is the number of the activated nozzles, qi is the actual flow rate for each nozzle
based on actual working pressure at the nozzle Pi (MPa).

3. Total water usage

Where Q is the total flow rate of the system, t is the water mist system activation time

4. Water mist system pipe design

The estimated pipe size can be calculated by

Where qv is the volume flow rate (m3/h), V is the flow velocity through the pipe (m/s)

5. Pressure loss due to friction

The pipe friction losses can be determined via Darcy-Weisbach calculation method

4
Table 2-2 shows the hydraulic calculation results for the water mist systems for EJMT. Other
design calculation results such as number of nozzles for each section, total water discharge rate
for the three-zone operation, water storage requirement for 60 min. of operation time are also
given in the Table.

Table 2-2: Design Calculation Results of Three Water Mist Systems (AQUAYS, FOGTEC,
HI-FOG) for EJMT

SUPPLIERS AQUASYS FOGTEC HI-FOG

88.9mmx3.05mm
(3.45’’x0.12’’);
114.3mm (O/D)
168.3mm (O/D) duplex stainless
Main Pipes Diameter (4.49’’)
(6.6”) steel
316 stainless steel
(EN/DIN:1.4462,
AISI:UNS31803)
21.3mmx2mm
(0.83”x0.078’’)
25mm (O/D)
Section Pipes 22 mm – 35 mm (O/D) High grade
(1’’)
(Longitudinal Branch Pipe) (0.87” – 1.38”) stainless steel
316 stainless steel
Diameter AIS1316TI
(1.4571)
48.2mmx2.8mm
(1.9”x0.11”)
Distribution Pipes 60.3mm (O/D)
42 mm (O/D) High grade
(From Section Valves to (2.37’’)
(1.65”) stainless steel
Branch Pipes) Diameter 316 stainless steel
AIS1316TI
(1.4571)
Number of Fire Zones
(Sections) for Each Tunnel
of EJMT (Eisenhower bore- 91 110 100
2724 m and Johnson bore
-2731 m long)
Number of Nozzles for
45 21 24
Each Zone (Section)
Total Water Discharge
3000 lpm 1800 lpm 3542 lpm
Rate For Operation of
(792.5 gpm) (475.5 gpm) (935.7 gpm)
Three Zones (Liter/min)

Water Storage 3 3 3
180 m 126 m 234 m
Requirement (for 60 min
(47551 gallon) (33285 gallon) (61816 gallon)
operation time)
 2.3 M ain C omponents and L ayout of a W ater M ist System for E J M T

The following subsections explain the main components and layout of the water mist system
proposed for EJMT.

2.3.1 Nozzles and nozzle layout

The water mist system is designed to cover the entire area of the tunnels by nozzles installed
at regular spacing. The nozzles are of open type and will be grouped into longitudinal zones
of 25 m (82 ft) to 30 m (98 ft) length along the tunnels. Three longitudinal nozzle rows are
proposed in every section. The nozzles will operate at a pressure range 35~ 50 bar (507 ~
725psi) for AQUASYS system, 50 ~ 100 bar (725~1450 psi) for FOGTEC system, and 80-
140 bar (1160~2030 psi) for HI-FOG system as tested in full scale tunnel fire tests.

The nozzle types and characterics of the AQUASYS, FOGTEC and HI-FOG systems are
listed in Table 2-1 and Appendices A, B, C. The layout of these nozzles for EJMT can also be
found in the same Table and Appendices. The nozzle type and layout parameters are all based
on full scale tunnel fire tests.

There are many supply and exhaust vents openings on the tunnel ceilings of EJMT, therefore
nozzles have to be carefully installed (e.g., in the middle of vents) to minimize the negative
impact of ventilation (see Figure 2-2 for an illustration of a portion of the water mist nozzles
layout proposed for EJMT).

Figure 2-2: Layout of water mist nozzles proposed for EJMT

2.3.2 M ain pipe and section pipes with nozzles

The pump system is connected to the section valves via a high pressure stainless main pipe.
The main pipe is water filled in the stand-by condition to reduce the time delay between
water mist system activation and discharge from the nozzles. The main pipe is pressurized to
around 10 bar (145 psi) or so (depending on detailed engineering design) in the stand-by
condition by means of a jockey pump 1.

1
A jockey pump is a small pump which is used to pressurize the main pipe to a suitable stand-by pressure.
The jockey pump compensates for small leaks. Any major leakages can be detected by monitoring the stand
by pressure. Jockey pumps work relatively often and therefore it is good practice to arrange a self cleaning
filter to ensure faultless operation.

6
The main pipe is connected to the sections pipes through distribution pipes. The nozzles are
installed at regular intervals to the section pipes (longitudinal branch pipe). Every section
(with a length of 25m to 30m, or 80 ft to 100ft) is closed towards the main pipe with a
remotely controlled section valve which is normally closed, which means sections (section
pipes) are normally dry. See Appendix B (4. section pipes) for a typical section pipes and
distribution pipes layout of the water mist system.

The main pipes, section pipes and distribution (or manifold) pipes are dimensioned via
hydraulic calculations by the suppliers and listed in Table 2-2.

The pipe materials for some of the water mist systems are also listed in the Table 2-2. To
fulfill UPTUN WP2 D251 [3], pipe material shall be tolerant against corrosion. The minimum
requirement is 1.4571/AISI316Ti. The material requirement is the same for all pipe
connectors (basically, the fittings and flanges). All parts of the connectors shall be made of
stainless steel in order to maximize the corrosion resistance and life time in tunnel
environment. To avoid the risk of galvanic corrosion the use of stainless steel and carbon
steel materials in the same piping connector is not permitted even if carbon steel is plated.

Installation of the pipe-work at the lower parts of the walls of the tunnels should be avoided
to eliminate damage of the pipes (which would in turn cause failure of the water mist system)
in the case of accidents. Having safe locations for critical components of a water mist system
is essential to have high reliability FFFS system. For EJMT, it is proposed to install the main
pipe, the section valves and control boxes in the supply air duct (see Figures 2-2,
2-3). Only the nozzle lines (section pipes with nozzles) will be installed on the tunnel
ceilings. This installation setup has been used for the Felbertauern Tunnel (with AQUASYS
system), which has a rather thin ceiling that cannot carry high loads. EJMT has the similar
issue with the tunnel ceilings as advised by CDOT (see Figure 2-4). Another benefit of
installing some of the water mist system components in the fresh air duct is that the WFS
components can be accessed at all time for maintanance with no need to close down the
traffic in the tunnels.

The exact locations of the main pipe and section pipes will be further assessed during the
final structural engineering design.
 Figure 2-2: Installation of a water mist system proposed for EJMT (the Felbertauern
Tunnel set-up: AQUASYS system)

Figure 2-3: Installation of the main pipe (the Felbertauern Tunnel with AQUASYS system)

8
 Figure 2-4: Typical north tunnel cross section (EJMT)

2.3.3 Section valves

UPTUN WP2 D251 indicated that that section valves shall be robust, remotely controlled and
fully leakage free. Only ball valves shall be used. Valves should be equipped with an adequate
drive. This can be either pneumatic, water hydraulic or electric. Valves shall not be activated by
thermal elements. Sections valves shall be provided such that a monthly test operation can be
carried out without allowing water to flow from the main pipe to the relevant section. If sections
valves are installed inside the tunnel they shall be protected by enclosures with a suitable fire
rating. Section valves should be equipped with suitable shut off means, which allow the
replacement of a section valve without draining water from the main pipe.

For EJMT, section valves will be located on the walls under the tunnel ceilings or inside the
supply air duct (see previous section 2.3.2) to ensure the reliability even in the case of an accident
in the tunnel.

For AQUASYS system, a total of 91 section valves (one per section) will be installed along one
tunnel (there are 182 sections in total for EJMT).

For FOGTEC system, a total of 110 section valves (one per section) will be installed along one
tunnel (there are 220 sections in total for EJMT).

For HI-FOG system, a total of 100 section valves (one per section) will be installed along one
tunnel (there are 200 sections in total for EJMT).

2.3.4 Pump stations

Recommended by UPTUN WP2 D251 [3], the total capacity of the pump unit shall be 110% of the
amount of water required to supply the protection area at the minimum pressure specific to the
nozzles. The recommended pump type for most tunnel applications is the triplex plunger pump,
because the available flow rates cover normal tunnel requirements. In addition, the constant high
pressure level, tolerant suction conditions and low filtration requirements are benefits when
compared to other pump types. It is recommended to limit the number of pumps used in fire
protection systems mainly because of the complexity of systems and the lifetime costs. A large
number of pumps will lead to complex pump unit arrangements and interactions between pumps,
and, a greater number of parts that will be subject to wear. The more moving parts a pump unit
consists of the greater potential risk of failure. The greater the number of moving parts and
components in general, for a pump system will increase the maintenance and lifetime costs. The
optimum design would be only one pump per system (plus a stand-by pump), however, due to the
high flow requirements in a tunnel application this is normally impossible to realize. The
necessary redundancy level is another factor which dictates the use of more than one pump.

From AQUASYS system, the required flow rate for the protection area is 3000 lpm@35 bar
(793 gpm @508 psi). Three electrically or diesel powered main pumps, two for normal operation,
one for back-up are proposed for EJMT. Each AQUASYS main pump unit has a capacity of
1800 lpm@64 bar (476 gpm@928psi). The power consumption for this design is 550 KW
(738 HP) for two main pumps operation. If two pump rooms are proposed, each of the pump
room would require a space 8.94m by 4.75~6 m (29 ft by 16~19 ft, see Appendix A) and one
more back-up pump is needed. For EJMT, only one pump room is proposed and installed right
next to the water reservoir at the west portal; the pump room of AQUASYS system would require
a space approximately 14 m by 4.75~6 m (46 ft by 16~20ft).

For FOGTEC system, the required water flow rate for the protection area is 1800 lpm@50 bar
(476 gpm@725 psi). Three main pumps, two for normal operation and one for redundancy, are
proposed for EJMT. Each pump unit has a capacity of 1051 lpm @115 bar (278gpm @1668psi).
The maximum power consumption for this design is 510 KW (684 HP). The pumps can be
equipped with electric or diesel driven motor. The pump room layout for the FOGTEC system is
shown in Appendix B. The pump room of FOGTEC system would require a space 11m by 6 m
(36ft by 20ft) and is proposed to be installed next to the water reservoir at the west portal of
EJMT.

For HI-FOG system, the required water flow rate for the protection area is 3542 lpm@80 bar
(936gpm@1160psi). Six SPU8 pump units, five for normal operation, one for redundancy, are
proposed for EJMT. Each SPU8 pump unit has electrical motors connected to 16 high pressure
pumps, and has a capacity of 779 lpm@140bar (206gpm@2030psi). The power consumption for
this design is 1080KW (1448HP). At the moment, HI-FOG does not have proper diesel units to
offer; they are investigating the issue and will get back with us when they have information
available about their possibilities to offer such big diesel units. The pump room of HI-FOG
system would require a space approximately 11.4 m by 8.07 m (37 ft by 26.5 ft ) and be installed
next to the water reservoir at the west portal of EJMT (see also Appendix C –3, 4).

High pressure pumps are equipped with a booster pump that keeps the most ideal working
conditions for the main pumps and maximizes the life time. A separate jockey pump unit will pre-
pressurize the wet main pipes in stand-by condition. Note that the pump rooms should always be
kept at a temperature above 4°C (39°F) in order to prevent freezing. The pump rooms should be
equipped with a suitable drainage and ventilation.

2.3.5 W ater r eser voir s

The high pressure pumps are supplied by fresh water from water tanks. The required minimum
operation time of the water mist system shall normally be 60 min for tunnels longer than 500 m
(1640 ft) or for a period of time that is double the time required for the emergency services to
reach the fire (taking into account worst case conditions such as traffic congestion) [3]. The
minimum operational time may increase if required by the authorities having jurisdiction.

The water volume requirement for 60 minutes operation is 126 m3 (33286 gallon) for FOGTEC
system, 180 m3 (44551 gallon) for AQUASYS system, 234 m3 (61817 gallon) for HI-FOG
system (see Table 2-2). The existing fresh water storage tank of EJMT is located at the west end
of the tunnels and has a volume of 454 m3 (120,000 gallon) [4], therefore the volume of this water
storage tank in EJMT is adequate for the operation time of 60 min. of a water mist system.

Noted that the water reservoir shall be of stainless steel, coated carbon steel, plastic or coated
concrete to avoid contamination of the water with rust or particles originally from the tank
structure itself [3]. Water reservoir shall be provided with a drain valve and an overflow outlet.
A manual ball valve shall be placed in the outlet of the reservoir for maintenance purposes.
Reservoirs shall be provided with venting to atmosphere to avoid over/under pressure. This
venting shall be protected by a breather filter to prevent the infiltration of particles into the
reservoir.

10
 2.3.6 Dr ainage r equir ement
UPTUN WP2 D251 [3] recommended that a drainage system is sized and designed such that it
will be sufficient to handle any liquids originating from accidents and water run-off, generated by
the water mist systems and the emergency services. NFPA 502 [2] also indicates the following:
• The drainage collection system shall be designed so that spills of hazardous or flammable
liquids cannot spread or cause flame propagation. The system shall intercept tunnel
roadway drainage from an arrangement of side gutter catch basins or other drain inlets,
such that the length of surface drain path from any potential spill point to the drain inlet is
minimized.
• The minimum design flow rate shall include, the design spill rate for fuel or other
hazardous liquids, the proposed water mist system discharge rate, discharge rate by the
emergency fire service, environmental sources (rain, snow, etc.), and any other
catchments sharing the tunnel drainage system piping. Where the tunnel roadway
drainage system discharges by gravity or by pumped discharge, it shall be provided with
a separator sufficient for the design spill rate for the hazardous liquids and with adequate
storage capacity.

The maximum demand on the drainage capacity for a water mist system proposed for EJMT is in
the range of 126 m3 (33286 gallon) to 234 m3 (61817 gallon), depending on type of water mist
systems used, for 60 minutes operation time. (Also note that a single large
flammable/combustible liquid tanker is approximately 8000 U.S. gallons from a single tank, or
16,000 gallons from a combination truck and trailer tanker.)

Further evaluation and design modification of the EJMT drainage system to sufficiently handle
effluent from a water mist system and any liquids from accidental spills is recommended in the
final design stage.

It should be noted that in some water mist system tunnel applications, AFFF was used to prevent
fires which are beyond the initial accident such as fires under the stopped vehicles. Particularly, if
burnable liquids are washed into the tunnel drainage system, the AFFF can prevent those
burnable liquids getting re-ignited by the hot surfaces. Although corrosion by AFFF is not a big
issue as all parts of the water mist system are made from stainless steel, the use of additives
introduces concern about possible negative effects on human health. (If AFFF is included in the
system, the total cost of the water mist system will increase by less than 3 %.)

2.3.7 A ctivation (fir e detection) and system contr ol

Once the fire is detected, the relevant section is either automatically or manually activated.
Three sections will be activated simultaneously. Water mist system will then encapsulate the
three section areas [75 m (246 ft) to 90 m (295f t) long]. The fire detection system is not
included in the budgetary quotation discussed in section 2.4.

2.3.8 F iltr ation, water quality and fr ost pr otection

Filtration is of great importance to the WMS functioning reliably. Water shall be pre-filtered
when filling up the water reservoir. For this purpose filters with a filtration grade of not higher
than 150 micron shall be installed at the tank inlet. Suitable filter means shall be provided
between the reservoir and the pump unit, of a filtration grade according to the table shown in
chapter 11.2.5.2 of UPTUN WP2 D251, to prevent particles which may have built up in the
reservoir over time entering into the supply system. Such filters shall:
- be 100% redundant or self cleaning
- provide a by-pass for the case of blocking
- be monitored
- have a sufficiently large filter surface.

Each nozzle or nozzle head shall be equipped with a strainer.

The water supply must be protected from frost. The pump system must be installed in a frost free
area. The main pipe must be protected from freezing where such risk exists (e.g., by trace heating;
the freeze protection is not included in the budgetary estimate).

AQUASYS proposed to use cycling of water rather than trace heating to protect the main
(wet) pipe from freezing. If the water temperature in the main pipe drops below 5°C (41F), the
jockey pump starts to keep the water in the main pipe flowing from the water tank through one
tunnel and returning to the tank through the other tunnel. Electric heaters at the jockey pump and
water tank may be necessay to keep the water temperature of above 5 to 8°C (41 to 46F)at all
times. And the main pipe must be equipped with thermal insulation. This approach has been
used in the Felbertauern Tunnel in the Austria, which is at an elevation of 1750 m (5740 ft) and
can be exposed to temperatures of -30°C (-22F) in winter. The cost increase with regarding to the
frost protection, according to AQUASYS, is marginal using this water cycling approach for the
Felbertauern Tunnel.

2.4 C ost E stimate

2.4.1 A QUA SY S system

Table 2-3 presents the detailed price estimate of AQUASYS water mist system for EJMT.
The budgetary quotation includes pump room installations (main pumps, jockey pumps, pump
room piping), main (pipe) lines through both tunnels, deluge valve units, section (nozzle) lines
and water mist nozzles in tunnels, water mist control system with interface to tunnel control
system, design and engineering, installation and commissioning of water mist system (WMS).
The budgetary quotation does not including the following: pump room building at the west portal,
fire detection system (preferable linear heat detection system), and acceptance by local
authorities. Items that can be sourced locally are also listed in the Table.

12
 Table 2-3: Budgetary Quotation of AQUASYS WMS for EJMT

No. Qty Unit Unit Price Total Price in € Total Price in US $

Design, Test,
1 Commissioning,
Project Management
2 Main Pumps
Pump Room
3
Installations
Main Pipe Line
(includes pipes,
4
hangers, brackets,
fittings)
Section/Nozzle
Lines (include
5
pipes, hangers,
brackets, fittings)
6 Water Mist Nozzles
7 Diverter Valve Units
8 Control System
9 Installation

Total System Price

item 4 Main line pipes, hangers, brackets, fittings could be sourced locally
item 5 Nozzle line pipes, hangers, brackets, fittings could be sourced locally
Item 9 Installation could be sourced locally
 2.4.2 F OG T E C system
Table 2-4 presents the detailed price estimate of FOGTEC water mist system for EJMT.

The budgetary quotation covers designs, materials, prefabrication and installation, testing and
commissioning, project management and commissioning of FOGTEC system.
Electrical/controlling limited to pumping rooms and section valve cabling/controlling is excluded
(which are to be connected to tunnel management/control system). Additional civil works, water
and power supply to pump rooms are excluded. Fire detection system (preferable linear heat
detection system), and acceptance by local authorities are also excluded. The costs are based on
European cost level and typical site conditions and installation programs. This cost estimate
excludes VAT and other possible taxes, import duties.

Table2- 4: Budgetary Quotation of FOGTEC WMS for EJMT

No. Total Price in € Total Price in US $

Design, Test, Commissioning, Project
1 Management, Transportation,
Insurances

Pump Stations (two) and Pump Room

2
Installations

Main Pipe Line (includes all straight

pipes, all pipe accessories such as
reducers, elbows, tees, fittings,
flanges, all supports and anchors for
3
piping, shutoff valves, drain valves
and venting valves); Main Pipe
Network Prefabrication and
Installation

Section/Nozzle Lines (include all

straight pipes, all pipe accessories
such as reducers, elbows, tees,
fittings, flanges, all supports and
4 anchors for piping); Section Valve
DN40 (with manual shut-off
maintenance valve); FOGTEC Water
Mist Nozzles; Section Lines
Prefabrication and Installation

Total System Price

14
 2.4.3 H I -F OG system

Table 2-5 presents the detailed price estimate of HI-FOG water mist system for EJMT.

The budgetary quotation includes mechanical and electrical installations, local project
management, all piping materials, pipe clamps, pipe fittings, spray (nozzle) heads, zone valves
placed in fire proof cabinets, main pipes, water filter packs, local I/O control cabinets, design,
engineering, installation work, project management and commissioning of HI-FOG system.

The budgetary quotation does not include the following: system control at the pump station, a
control system and its equipment for the zone valve operation (main control system = SCADA or
similar), fire rated cables between the local control cabinets and zone valves for the valve
operation, pipes trace heating and insulation if required, water reservoir, feed water pump, water
supply, power supply, civil works, pump room building and its equipment, fire detection for fire
indication, main control system (SCADA or similar) which is to be connected to local I/O units
and pump room control interfaces to operate the whole system (valves and pumps).

The calculated installation price does not include the following: dismantling and reinstalling of
tunnel lining or other equipment disturbing water mist piping or nozzles or installation, extra
bracketing which may be required, night time working rates, cost for storage area at site, cost for
logistics at site and required security services. (The local installation cost varies from country to
another depending on local conditions, requirements and workman cost. This price estimation is
based on the tunnel installation projects HI-FOG experienced in other countries. It should be also
noted that during a wide refurbishment work in a tunnel the installation time could be longer due
to difficulties with logistics and schedules in conjunction with other works. Therefore this
installation costs are budgetary only and will need to be finalized based on US contractor
requirements and any special project considerations not identified in this estimation).

Table 2-5: Budgetary Quotation of HI-FOG WMS for EJMT

No. Qty Unit Total Price in US $

Design, Test,
1 Commissioning, Project
Management
2 Pump Room Components
3 Pump Room Installations
Main Pipe Line (includes
4 pipes, hangers, brackets,
fittings)
Nozzle Lines (include pipes,
5
hangers, brackets, fittings)
6 Water Mist Nozzles
7 Diverter Valve Units
8 Control System
9 Installation

Total System Price

 2.5 M aintenance

A strict and regular maintenance program shall be followed to ensure the reliable operation of the
water mist system. The property owner and the operator of the system shall be responsible for
this program. Maintenance shall be carried out in accordance with the design, installation, and
maintenance manual of the manufacturer. UPTUN WP2 D251 [3] indicates that the regular
maintenance shall at least cover the following:
• Monthly pump test runs for a minimum of 10 min. without pressurizing the pipe work in
the tunnel; where applicable, all pumps of one pump unit shall be tested simultaneously
• Monthly test of all section valves (test by operation)
Note: Section valves do not normally have any redundancy.
• Monthly collecting of information on running times of jockey pumps and automatic
filters in order to detect leaks and water quality problems.
• Quarterly visual inspections of piping and nozzle heads.
• Twice a year (minimum) the system shall be maintained in accordance with the
manufacturer's instructions by a company authorized by the manufacturer.
• Every five years pressure testing of the pipe work with 150% of the working pressure for
one hour.

The operator's inspection program is intended to detect faults at an early stage to allow
rectification before the system may have to operate. The manufacturer shall provide the tunnel
operator with a monitoring software collecting the history of service and maintenance activities,
running times of the pump system, failure reports etc. The software shall include instructions on
actions to be taken in case of faults and malfunctions.

NFPA 750 [5] also indicates that the frequency of inspections of components of water mist
systems shall be in conformance with the manufacturer’s listing requirement and NFPA 25 [6].
NFPA 25 suggests that the frequency of inspection and tests shall be in accordance with Table
12.1.2 (also listed in Table 2.6 of this report) or as specified in the manufacturer’s listing,
whichever is more frequent. Scheduled maintenance shall be performed as outlined in Table
12.2.4 of NFPA 25 (also listed in Table 2.7 of this report).

16
 Table 2-6: Maintenance of Water Mist Systems

Semi-
Item Task Weekly Monthly Quarterly Annually Other
annually
Check source pressure. x
Water supply Check source quality (*first year). x* x
(general)
Test source pressure, flow,
x
quantity, duration.
Check water level (unsupervised). x
Check water level (supervised). x
Check sight glass valves are
x
open.
Check tank gauges, pressure. x
Water storage Check all valves, appurtenances. x
tanks
Drain tank, inspect interior, and
x
refill
Inspect tank condition (corrosion). x
Check water quality. x
Check water temperature Extreme
weather
Inspect general condition,
x
corrosion.
Additive Check quantity of additive agent. x
storage
cylinders Test quality of additive agent. x
Test additive injection, full
x
discharge test.
Check water level (unsupervised). x
Check water level (supervised). x
Inspect supports, attachments. x
Test low water level alarm. x
Check water quality, drain, flush
Water x
and refill
recirculation
Test operation of float operated
tank x
valve.
Test pressure at outlet during
x
discharge
Test backflow prevention device
x
(if present).
Inspect and clean filters, strainers,
x
cyclone separator.
 Table 2-6: Maintenance of Water Mist Systems (continued)
Semi-
Item Task Weekly Monthly Quarterly Annually Other
annually
Inspection, testing, and
maintenance
shall be in accordance with the
Pumps and
requirements of NFPA 20, x x x x x
drivers
Standard for the Installation of
Stationary Pumps for Fire Protection,
and NFPA 25.
Check outlet water (standby)
x
pressure.
Standby pump
Test start/stop pressure settings
x
for standby pressure.
Inspection, testing, and
System control maintenance shall be in
x x x x x
valves accordance with the requirements
of NFPA 25.
Inspection, testing, and
maintenance
shall be in accordance with the
Control
requirements of NFPA 72,
equipment
National Fire Alarm and Signaling
Code

Inspection, testing, and

maintenance shall be in After
x x x x x discharge
accordance with NFPA 25.
Water mist
system piping
Inspect sample of nozzle screens
and nozzles
and strainers (see 10.5.1.4 of
NFPA 750)

Enclosure
features, Inspect enclosure integrity. x
interlocks
Test interlocked systems (e.g.,
x
ventilation shutdown).
Ventilation
Test shutdown of fuel/lubrication
x
systems.

Table 2.7 Maintenance Frequencies

Item Activity Frequency

Water tank Drain and refill Annually

System Flushing Annually

Strainers and Clean or replace After system
filters as required operation

18
References

1. PIARC 2008: Road Tunnels: An Assessment of Fixed Fire Fighting Systems.

2. NFPA 502, Standard for Road Tunnels, Bridges, and Other Limited Access
Highways, 2011 Edition, National Fire Protection Association.
3. UPTUN, Engineering Guidance for Water Based Fire Fighting Systems for the
Protection of Tunnels and Sub Surface Facilities. Work Package 2 of Fire development
and mitigation measures, Research Project UPTUN of the European Commission,
Document D251, by Toby McCory, Dirk Sprakel, Erik Christensen, 2008.
4. Risk Analysis Study of Hazardous Materials Trucks through Eisenhower/Johnson
Memorial Tunnels, June 2006, PB.
5. NFPA 750, Standard on Water Mist Fire Protection Systems, 2010 Edition, National
Fire Protection Association.
6. NFPA 25, Standard for the Inspection, Testing, and Maintenance of Water-Based Fire
Protection System, 2011 Edition, National Fire Protection Association.
7. NFPA 13, Standard for the Installation of Sprinkler Systems, 2010 Edition, National
Fire Protection Association.
8. NFPA 15, Standard for Water Spray Fixed System for Fire Protection, 2007 Edition,
National Fire Protection Association.
9. Water Mist Fire Suppression Systems for Road Tunnels, Final Report, the SOLIT
Research Project, 2007.
10. The HIFOG Truck Fire Tests Reports 2004 - 2007.
11. AQUASYS Preliminary Design Submission 2012.
12. HI-FOG Preliminary Design Submission 2012.
13. FOGTEC Preliminary Design Submission 2012.
20
Appendix A: Preliminary Design Drawings of a Water Mist System for EJMT: AQUASYS System

Drawings include
1. Nozzle Layout
2. Nozzle Head Characterics
3. Diesel Powered Motor Pump
4. Electrical Powered Motor Pump
5. Pump Room Layout
 1 2 3 4 5 6 7 8 9 10 11 12

Nozzle Layout
A A

main line

Diverter Valve Box

B B
return air ventilation duct supply air ventilation duct nozzle lines

4876 mm (16ft)

4000 mm (13ft)

740 mm (2.4ft)

C 1040 mm
C

4000mm 4000 mm (13 ft)

10667mm (35 ft)

D D

1000 mm 2000 mm (6.6 ft)

1000mm (3.3ft)
typical tunnel section 30m (98.4 ft)

Nozzle Line
E E
4000mm (13 ft)

Nozzle Line
40000mm

F F

Nozzle Line

G G
30000 mm (98.4 ft) Änderung Anz.d.Änd Änderungsinhalt Datum Erstellt Geprüft
Revision No.of Mod Modification Date Prepared Checked
Gez.
Urheberschutz gemäss
Copyright according to Prep. ps 111123 Maßstab / Scale Masse / Weight

ISO 16016 Gepr.

Check.
ps 111108 1:1 0,0 kg
Allgemeintoleranzen (Freimaßtol.): Blatt von
Untoleranced dimensions:
DIN ISO 2768 -m -K
POSTFACH 100, INDUSTRIEZEILE 56, A - 4021 LINZ
TEL ++43 732 7892 449 FAX ++43 732 7892 373
Sheet 1 of 1
DIN EN ISO 13920 - A - F info[at]aquasys.at
Project Kunde: Material Wärmebehandlung /
Projekt Customer: Material heat treatment
Edelstahl 316L .
1.4404 .
H H
Benennung/Designation
Zng.Nr. Format Änderung
tunnel Drawing No. Format Revision

A300101-06489 2 B
Material Nr.
Material No.

1 2 3 4 5 6 7 8 9 10 11 A2
C:\Programme\Solid Edge V12\Program\Template\ASNormal_Gewicht_Material.dft
 C:\Dokumente und Einstellungen\kh\Desktop\Praj\AS-DB-DKIT-A.doc
kh,2011-05-01

DKIT
In Line - Nozzle Head In Line - Düsenkopf

• Tunnel configuration: • Tunnelausführung:

- AISI 316 L, Stainless Steel - V4A, Edelstahl
- pressure stage: PN 64 - Druckstufe: PN 64

Standard
Type k - factor Maße / Dimensions

DKIT 38 118 x 42
(4.6 in x 1.6 in)
other configurations on request andere Konfigurationen auf Anfrage

DKIT 38 / 0 – 6.90 – x L

flow rate l/min @ 100 bar,

e.g.: 38 = 38 l/min @ 100 bar

0 - 6.90 : AQUASYS internal code

pipe dimension x L : e.g. 22L

 C:\Dokumente und Einstellungen\kh\Desktop\Praj\AS-DB-DVST2-A.doc
kh, 2011-05-01

DVS
Diverter Valve System Bereichsventileinheit

• Configuration for 2 sections: • Standardausführung für 2 Sektionen:

- Stainless steel AISI 316 L - V4A Edelstahl
- pressure stage: PN 64 - Druckstufe: PN 64
- additional test port - zusätzlicher Messanschluss
- scavenge port (air) - Anschluss für Spülluft
- service ball valve with position monitored - Servicekugelhahn mit überwachter Endlage
- power supply 230 VAC - Stromversorgung 230 VAC
- pressure switch - Druckschalter
- pressure gauges - Druckmanometer
• Options: • Optionen:
- 24 VDC - 24 VDC

Type L x B x H (mm)
DVS 42L-230VAC ST ca. 1300 x 400 x 700
4.3 x 1.13 x 2.3 (ft)
other configurations on request / andere Ausführung auf Anfrage

DVS T2 - 230VAC ST
Type: DVS T2 = for 2 Sections
DVS T4 = for 4 Sections

Voltage: 230 VAC

24 VDC

ST - AQUASYS internal code

 S:\TECHNIK\Datenblätter\Aquasys\AS-DB-PP-1500E-1800E-A.doc
kh, 2011-01-05

PP 1500 E
PP 1800 E
Electric Power Pack Tunnel

• Standard configuration: • Standardausführung:

Electrically powered motor-pump unit Elektrisch angetriebene Motor-Pumpeneinheit
pump for pure potable water Pumpe für Trinkwasser
pressure relief valve, pressure switch Druckbegrenzungsventil, Druckschalter
built in performance test unit, eingebaute Leistungsmessung,
protection class: IP 54 Schutzart: IP 54
maximum pressure: 64 bar maximaler Druck: 64 bar
required pressure stage: PN 64 erforderliche Druckstufe: PN 64
• Options: • Optionen:
- soft start control - Soft Start Anlauf
- frequency converter for flow rate control - Frequenzumrichter zur Regelung der
Förderleistung

other configurations on request andere Ausführungen auf Anfrage

Type Maße/dimensions Gesamtgewicht / total weight Power / Voltage

LxBxH main pumps
PP 1500 E 2800 x 1200 x 1500 mm ca. 1.750 kg 230 kW / 400 VAC
PP 1800 E 2800 x 1200 x 1500 mm ca. 1.800 kg 275 kW / 400 VAC
9.2 x 4 x 4.9 (ft) 308 HP/400 VAC
PP 1500 / 64 - E - 0001 369 HP/400VAC

Flow rate : 1500 l/min @ 64 bar 0001 - AQUASYS internal code

1800 l/min @ 64 bar

Type of drive: E = Electric motor

 C:\Dokumente und Einstellungen\kh\Desktop\Praj\AS-DB-PP-1500D-1800D-A.doc
kh, 2011-01-05

PP 1500 D
PP 1800 D
Diesel Power Pack Tunnel

• Standard configuration: • Standardausführung:

Diesel powered motor-pump unit Diesel Motor-Pumpeneinheit
pump for pure potable water Pumpe für Trinkwasser
pressure relief valve, pressure switch Druckbegrenzungsventil, Druckschalter
built in performance test unit, eingebaute Leistungsmessung,
Diesel tank Kraftstofftank
redundant starting batteries packs redundante Starterbatterien- Sätze
protection class: IP 54 Schutzart: IP 54
maximum pressure: 64 bar maximaler Druck: 64 bar
required pressure stage: PN 64 erforderliche Druckstufe: PN 64
• Options: • Optionen:
- pump start control - Steuerung für Pumpenstart
- redundant battery charging unit - redundantes Batterieladegerät

other configurations on request andere Ausführungen auf Anfrage

Type Maße/dimensions Gesamtgewicht / total weight Power / Voltage

LxBxH main pumps
PP 1500 D 4100 x 1300 x 2000 mm ca. 3.600 kg 230 kW (308 HP)
PP 1800 D 4100 x 1300 x 2000 mm ca. 3.700 kg 275 kW (369 HP)
13.4 x 4.3 x 6.6 (ft)
PP 1500 / 64 - D - 0001
Flow rate : 1500 l/min @ 64 bar 0001 - AQUASYS internal code
1800 l/min @ 64 bar

Type of drive: D = Diesel engine

 1 2 3 4 5 6 7 8 9 10 11 12

A A
section A-A

B B

C C

D D

1502 mm (4.9 ft)

672,3 mm (2.2 ft)
Water Storage Tank

E E
4750 mm (15.6 ft)

1130PPIW
870PPIW
F F
1220 mm
(4 ft)
jockey pump
1750mm (5.7 ft)

2300PPIW 233

(0.76 ft)
G 2782PPIW G

A Änderung
Revision
Anz.d.Änd
No.of Mod
Änderungsinhalt
Modification
Datum
Date
Erstellt
Prepared
Geprüft
Checked
Gez.
Urheberschutz gemäss
Copyright according to Prep. ps 110407 Maßstab / Scale Masse / Weight

ISO 16016 Gepr.

Check.
ps 110407 1 : 20 0,0 kg
7370 mm (24.2 ft) Allgemeintoleranzen (Freimaßtol.): Blatt von
Untoleranced dimensions:
DIN ISO 2768 -m -K
POSTFACH 100, INDUSTRIEZEILE 56, A - 4021 LINZ
TEL ++43 732 7892 449 FAX ++43 732 7892 373
Sheet 1 of 1
8940 mm (29.3 ft) DIN EN ISO 13920 - A - F info[at]aquasys.at
Project Kunde: Material Wärmebehandlung /
Projekt Customer: Material heat treatment

- - - .
- .
H H
Benennung/Designation
Zng.Nr. Format Änderung
Pumproom Drawing No. Format Revision

typical example A300600-06052 2 A

Material Nr.
Material No.
-
1 2 3 4 5 6 7 8 9 10 11 A2
C:\Programme\Solid Edge V12\Program\Template\ASNormal_Gewicht_Material.dft
 Appendix B: Preliminary Design Drawings of a Water Mist System for EJMT: FOGTEC System
Drawings include
1. Nozzle Layout (Cross Section)
2. Hydraulic Design
3. Pump Room Layout
4. Section Pipes
5. Trace Heating
mm (35 ft)
(16 ft)
 (82 ft)
(2263 ft)
PROJECT - Hatch Mott MacDonald
13.3 Pump room lay-out
moin pipe ON100
Suc·tron line ON 200
t o t he Tunnel
2 + 1 x 1050 1/min pump unit from the tank
Olesel driven is shown
alternative electrornotot driven
Return line DN 125
to the tank
(2263 ft)
(5.2 ft)
(1.3 ft)
(1.3 ft)
(5.2 ft)
Fogtec Control Cobinet Fogtec Control
tf elctricmotor driven system Cabinet
(4.3 ft)
(36.1 ft)
...... ......
-- =·
AlpkniWifl
"'""
Rl M<~
OIIH7..
SV•t••
t)sh•

~ Nl.e:::.M;-
~
"""'
Typical puflllrOOil for 2 + 1x 1050 linin
"·'""'
T.lrtflk• """"""'
Syst••
with deseloreled ricnotors
--
FOOTEC"
''''""
l d ctn.ngt-Nr,
fhltlntlilo.
FOG_ 10101221-003 ...
t. tn 1
FOGTEC Brandschutz GmbH & Co. KG, Schanzenstral!.e 19A, 51063 KOin, 'If +49 (0) 221 / 96223-0
These documents are sWject tocopyrl;;ht. AI rights regarding mnlents are reserved, particular1y those pertaining lo <Xll'frighl Airy i11ringement of our rights v.il be prosec:uted These documents have to be treated confidentially and may oot be photocopied OOf made available kl tttn:l part.es without our permissiOn and are to be retume<l \cl us on request
 49
PROJECT- Hatch Matt MacDonald
8f.:Q�T��4D
13.4 Section pipes

The schematic section design is presented in the following picture. The yellow pipe is the main pipe
and the rest are section pipes. Nozzles are installed with the regular intervals to the longitudinal
branch pipes (green colour). The length of one section is 25 meters. The picture below demonstrates
the typical section. There are 6 nozzles in 25 meter installed to every branch pipe of meter tunnel.
(82 ft)
This equals to 21 nozzles per section. The distance between nozzles is 4.17 meters.
(82 ft)
(13 ft)

The sections are normally built with offsite prefabricated pipe kits in order to make installation in the
tunnel faster. The following picture shows the main parts in larger view.

FOGTEC Brandschutz GmbH & Co. KG, Schanzenstra�e 19A, 51063 Koln � +49 (0) 221/96223-0 ,

These documents are subject to copyright. All rlghts regarding contents are reserved, particularly those pertaining to copyright. Any infringement of our rights will be prosecuted These documents have to be
treated c011fidentially and may not be photocopied nor made available to third parties without our permission and are to be returned to us on request.
Appendix C: Preliminary Design Drawings and Specification of a Water Mist System for EJMT:
HI-FOG System

Drawings include
1. Nozzle Layout for EJMT
2. Nozzle Head Characterics (4S 1MD 6MD 1000)
3. SPU Pump Unit for North America (Specification)
4. Pump Room Layout
5. Valve Cabinet
6. Assembly Body
7. Specification for Water in HI-FOG Systems
 (90 ft)
(1 in)
(11.2 ft)
(2.4 in)
(11 ft)
mm (4.5 in)
(35.4 ft)
(16.2 ft)
 Technical Data Sheet TC9840
Spray Head Type 4S 1MD 6MD 1000
HI-FOG ® Stock code C31102 17 Nov 2006

Centre nozzle
Ø34,5 mm (1.4 in)

Cone nozzles (x 6)

Strainer
Thread for assembly
47 mm (1.9 in)

body connection
O-ring (15 x 1,5 NBR 70 Shore)
Bonded seal
Spray head body
21 mm
(0.8 in)

General Body material Stainless steel

Ma s s 0 , 1 3 9 kg

K -fa c tor 5 , 5 lpm/ba r 0,5

Installation Location* Tunnel ceiling and/or walls

Max. spacing* 4 m (13.1 ft)

Typical Road and railway tunnels.

application

*) Application specific

Marioff Corporation Oy, P.O. Box 86, Virnatie 3, FIN-01301 Vantaa, Finland,
tel +358 9 870 851, fax +358 9 8708 5399, e-mail info@mariof f.fi, www.hi-fog.com
Marioff Corporation Oy reserves the right to revise and improve its products and recommended system configurations as it deems necessary without notification. The information contained herein is
intended to describe the state of HI-FOG products and system configurations at the time of its publication and may not reflect the product and/or system configurations at all times in the future.
 Pump Unit for North America
Overview of SPU products
TECHNICAL DATA SHEET DOC0004nnn REVISION Draft 1 DATE OF ISSUE Aug 2010

Description
The Sprinkler Pump Unit (SPU) for North America is designed to meet the requirements HI-FOG® Water
Mist Fire Protection Systems on land-based applications, and is especially suited for systems requiring
project specific approvals by NFPA. The SPU pump modules are started sequentially upon activation to
reduce the electric power peak loads. In stand-by position the system pressure is maintained at 25 bar by
means of a stand-by pump.

The SPU for North America can be started automatically, manually or remotely. The automatic start is
activated by flow or by low pressure, both of which are continuously monitored. The manual start is
activated from the pump controllers. The remote release can be included to allow activation by release
panel or third party signal (such as a fire detection system, FDS).

The SPU for North America is stopped manually by pressing the STOP button on each pump controller
after the section valve of the release area has been closed. Closing the section valve stops the water
release and allows the pressure in the pipes to rise back to 140 bar.

Service area requirement

Reserve free space around the unit available for service and maintenance work per the instructions
provided in the Marioff Installation Manual.

Starter Cabinet (pump controllers)

The Starter Cabinets for SPU for North America products consists of power supply section, control
section, and a specified number of controller sections. The Starter Cabinet is used to monitor, operate,
and control the SPU pump unit. It indicates all operation and fault signals concerning the pump unit.

The SPU for North America may include the following signals out for use by a third-party system:

 PUMP RUNNING – HI FOG ACTIVATED

 PUMP UNIT – PLC FAULT
 SYSTEM PRESSURE LOW
 POWER AVAILABLE
 PHASE REVERSAL
 LOW WATER SUPPLY

For the manufacturer’s product details, please visit; www.tornatech.com or www.cutlerhammer.com.

For more information, see Technical Data Sheet DOC000nnnn.
 Pump Configurations

E01234.3 SPU-2 E01235.2 SPU-3 E01236.2 SPU-4

Remote Cutler Hammer Controller Remote Cutler Hammer Controller Remote Cutler Hammer Controller

Picture Not
Available

E01237.3 SPU-5 E01238.2 SPU-6 E01238.3 SPU-6

Skid Mounted Tornatech Controller Remote Cutler Hammer Controller Skid Mounted Tornatech Controller

E01238.4 SPU-6 (Canada Supply) E01058.2 SPU-8 E01058.3 SPU-8

Skid Mounted Tornatech Controller Remote Cutler Hammer Controller Skid Mounted Tornatech Controller

Picture Not
Available
 Technical Specifications

Pump Unit Electric Supply Discharge Flow Discharge Inlet H2O Inlet H2O Flow Inlet Air Inlet Air
Options (60hz) LPM (GPM) Pressure Pressure BAR LPM (GPM) Pressure Flow
BAR (PSI) (PSI) BAR (PSI) NL/MIN
(CFM)
SPU-2 195 (51) 2-7 (29-101) 195 (51) 4-7 (58-101) 150 (5.3)
SPU-3 292 (77) 2-7 (29-101) 292 (77) 4-7 (58-101) 150 (5.3)
SPU-4 390 (103) 2-7 (29-101) 390 (103) 4-7 (58-101) 150 (5.3)
600V 3PH 60HZ
SPU-5 487 (128) 140 (2,030) 2-7 (29-101) 487 (128) 4-7 (58-101) 150 (5.3)
460V 3PH 60HZ
SPU-6 584 (154) 2-7 (29-101) 584 (154) 4-7 (58-101) 150 (5.3)
SPU-7 682 (180) 2-7 (29-101) 682 (180) 4-7 (58-101) 150 (5.3)
SPU-8 779 (205) 2-7 (29-101) 779 (205) 4-7 (58-101) 150 (5.3)

Pump Unit Water Inlet Water Outlet Air Inlet Drain Outlet Overflow Running Lock Rotor
Load Amps Amps
(RLA) (LRA)
BSP R1,1/2"
SPU-2 Female 30X2.5 DN2353 SAE 2 1/2" Flange
SPU-3 DN50 DIN2642 30X2.5 DN2353 SAE 2 1/2" Flange
SPU-4 BSP R 2" Female 38X3 DIN2353 SAE 2 1/2" Flange
BSP R1/4" BSP R3/4"
42 225
SPU-5 DN65 DIN2646 38X3 DIN2353 Female Female SAE 2 1/2" Flange
SPU-6 DN65 DIN2647 38X3 DIN2353 SAE 2 1/2" Flange
SPU-7 DN100 DIN2633 SAE 2" DN125 DIN2642
SPU-8 DN100 DIN2633 BSP R2" Female DN125 DIN2643

Pump Unit Width Length Height Mass (Dry) Mass (Wet)

mm (in) mm (in) mm (in) Kgs (lbs) Kgs (lbs)

SPU-2 1000 (39.3) 1739 (68.5) 1248 (49.2) N/A N/A

SPU-3 1000 (39.3) 1739 (68.5) 1694 (66.7) 1770 (3902) 2300 (5071)

SPU-4 1410 (55.5) 1800 (70.9) 1800 (70.9) 1890 (4167) 2450 (5401)

SPU-5 1410 (55.5) 1800 (70.9) 1800 (70.9) 2400 (5291) 2960 (6525)

SPU-6 1410 (55.5) 1800 (70.9) 1800 (70.9) 2700 (5953) 3260 (7187)

SPU-7 1410 (55.5) 1925 (75.8) 2322 (91.5) N/A N/A

SPU-8 1410 (55.5) 1925 (75.8) 2341 (92.2) 3100 (6834) N/A

SPU-5 (S) 1442 (56.7) 2456 (96.7) 2044 (80.5) 2600 (5732) 3160 (6967)
SPU-6 (S) 1442 (56.7) 2456 (96.7) 2044 (80.5) 2894 (6380) 3454 (7615)

*(S) denotes a SPU unit to be delivered as a skid with Tornatech cabinets mounted to a larger base
*Power requirements shall be based on the running load amps for all but 1 pumps running plus the lock rotor amps for one pump.
*RLA and LRA are calculated based on 460V-3PH-60Hz motors
SPU – x Sequence of Operations
The SPU-x installation and operation are governed primarily by NFPA 20 as well as the approval
documentation of Factory Mutual for light-hazard applications. There are two ways that an idle pump unit
can be started; they are by the automatic sequence and by manually starting and stopping each motor.
The first operation to be covered is the starting and stopping each motor manually.

On each motor controller within the cabinet, there is separate start and stop push buttons that control
each motor independent of the PLC programming. The PLC does, however, receive a signal each time
the button is pushed. This is done to keep the PLC from activating the automatic sequence while a motor
is being run for maintenance purposes or for other reasons. A signal will still be sent to the fire alarm
panel (if option exists) that the system has been activated which is done for obvious reasons, you do not
want someone to inadvertently run the pumps without someone else who is monitoring the system
knowing about it. Once a pump is run and system pressure is high on the pipe network, the system will
automatically reset the system pressure down to its standby pressure and return to auto-ready mode.

The automatic sequence mode is rather simplistic in concept although can be somewhat complex to try to
end once started. If significant work is to be done on a system, it is often best to take the PLC out of run
mode by flipping a hidden switch under a cover on the face of the PLC to the opposite position (off).
Altering the position of this switch will automatically send a ‘PUMP UNIT FAULT’ to the monitoring fire
panel to alert those monitoring the system of an error. It is very important to note that this switch must be
returned to the ‘RUN’ position once the work is completed and the standby pressure is back to its normal
pressure of 25-30bar. Failure to do so may activate the automatic mode once the PLC switch is set to
‘RUN’. The automatic mode once activated will run for a minimum of 10 minutes per NFPA 20 before it
will shut down and reset itself. Activation of the automatic sequence can be accomplished in two ways,
either by a detection of steady flow or by a drop in system pressure.

Flow Start:
There is at least one flow switch on the pump unit that is located on the output of the standby pump.
There may be other flow switches installed throughout the system if so required. These flow switches all
have a programmable set-point that will close the circuit when the flow reaches that set-point. If flow is
detected at any PLC monitored flow switch for a period of 4 seconds, the PLC will start the motor
sequencing.

Pressure Start:
There is an analog pressure switch that is being monitored by the PLC that will give the exact pressure of
the system at all times. The low pressure start is typically set to start the motor sequencing when the
system pressure drops below 17bar. Once this signal has been received, there is a 10 second delay to
protect against false starts and accidental trips. If the pressure remains below 17bar for the complete 10
seconds, the PLC will start the motor sequencing.

Motor Startup Sequencing:

Once either of the two ways to start the auto sequence has been initiated, it is recommended that the
system be allowed to cycle through its sequence. Any disruption to this sequence may cause the motors
to inadvertently start again within 10 seconds of being shut down. This occurs partly due to the NFPA 20
directive that states the pump must run for a minimum of 10 minutes once it has been activated and also
may be the result of low system pressure or a flow switch still showing a flow condition. If it becomes
absolutely necessary to stop the sequence, the safest way is to reset the PLC using the RUN/STOP
switch discussed previously and not to turn back to RUN until the system is in standby mode, meaning no
flow and system pressure at 25-30bar.
Once a signal is received to start the lead motor, the PLC will activate the pump run contacts on the
controller relevant to Motor 1. The PLC will then monitor the pressure on the analog pressure switch for a
period of 4 seconds following the startup of motor 1. If this pressure stays below the set-point of 90bar
(typically), the PLC will then signal the controller for Motor 2 to start the motor. This sequence will
continue for the number of motors installed on the pump unit. The motors will continue to run as long as
the pressure remains below their individual shutdown set-points as described in the section below.
Motor Shutdown Sequencing:
Each motor installed on the pump unit is powering two individual pumps. These pumps have separate
unloader valves that are to be set at varying pressure levels upon system commissioning, or if preset at
factory, verified at commissioning. Typically the two pumps are set in tandem to the same pressure for
each motor. The PLC program will have a preset value for the shutdown pressure of each pump. The
pressure of the system must reach the highest set-point for the last motor that was started for the system
to start shutting down motors. The set-point must be kept for a period of one minute before the PLC will
discontinue its run signal to that motor controller. If once the PLC shuts the motor down, the system
pressure drops below the 90bar set-point, the PLC will restart the motor. Once the system has been
closed, and the flow and pressure have been stabilized, the PLC will shut down any remaining motors in
sequence with 1 minute intervals between each motor. The final motor (motor 1) will run for a time period
that is a minimum of 10 minutes from the shutdown of the last pump.

System Reset:
Following an automatic shutdown, the system will remain static for a period of 30 seconds before opening
a stabilization valve which will return the system pressure to its original 25-30bar.*

*note: some systems have an optional manual reset which will flash calling for someone to push a button
to reset the system.
 mm (26.5 ft)

(37.4 ft)

mm (11.9 ft)
 Technical Data Sheet DOC0002339 Page 1 of 2

Valve cabinet SAE 2” – SAE 2”

Product D90022 5 May 2008

Manual release valve Hydraulic work cylinder

Electric motor driven
directional valve

Overflow

Cable gland

(2.1 ft)

Electric junction
box

640
Pressure
gauge
Tube to section
Main (dry in stand-by
distribution mode)
tube from
the pump
unit

604 mm (2 ft)

Shut-off valve (Normally Microswitch (on every valve Hydraulically operated

open. Closed during for valve position signal) section valve (closed in
maintenance.) stand-by mode)

Valve cabinet The valve cabinet is used to protect the valves. It has a lockable door to prevent any
unauthorized access to the valves. The manual shut-off valve is operated by using a handle
inside the cabinet.

General Box material Stainless steel plate 1.4301 EN (AISI 304), thickness 1 mm (0.04 in)

Box size (mm) width 604, height 640, depth 322 (box 200, door 120)
(2 ft) (2.1 ft) (1.1 ft) (0.66 ft) (0.4 ft)

Fastening holes (mm) width 30, height 9

(0.1 ft)

Thermal isolation Ceramic fire protection wool 2 x 30 mm, material Paroc FPS 14
Ceramic fire protection cord 25 x 25 mm, product Finlon ceramic cord
(0.08 ft)

Specifications The cabinet design is validated in the following conditions:

+ 400 °C continuous temperature outside, duration > 1 hour
+ 800 °C continuous temperature outside, duration > 0,5 hours

Marioff Corporation Oy • Virnatie 3 / P.O.Box 86, FI-01301 Vantaa, Finland

Tel. +358 (0)9 870 851 • Fax +358 (0)9 8708 5399 • www.marioff.com

© Marioff Corporation Oy 2008.

 Technical Data Sheet DOC0002339 Page 2 of 2

Valve cabinet SAE 2” – SAE 2”

Product D90022 5 May 2008

11 2
Valve cabinet components
1. Hydraulically operated section valve
(closed in stand-by mode)
3
2. Hydraulic work cylinder
3. Manual release valve
4
4. Electric motor driven directional valve
5. Pressure gauge 9
6. Shut-off valve (normally open
- closed during test work)
7. Main distribution pipe from the pump unit
8. Pipe to the section (dry in stand-by mode)
9. Overflow 5
10. Shut-off valve (normally open
- closed during maintenance) 14 12
11. Manual release valve position limit switch
12. Section valve open limit switch 10
13. Section valve closed limit switch
14. Shut-off valve position limit switches
7 6 1 8
13

Operation principle
In stand-by mode, the pipe from the main distribution pipe (7) to hydraulically operated section valve (1) is pressurized by
stand-by pressure. Water pressure effects (via shut-off valves (6) and pipe section in question) in a hydraulical work
cylinder which operates the section valve (1) and in other components inside the valve cabinet.

1. Manual release
In manual release, a manual release valve (3) is turned to manual release position, thus generating a pressure difference
in the hydraulic work cylinder (2) and forcing the piston to open the hydraulically operated section valve (1) which allows
water flow to section pipe (8).

2. Remote release from control panel

The electric motor driven directional valve (4) can be remotely operated. In remote release, the directional valve (4) is
turned to remote release position, thus generating a pressure difference in the hydraulic work cylinder (2) and forcing the
piston to open the hydraulically operated section valve (1) which allows water flow to the section pipe (8). In case of electric
black-out, the valve will stay in its last position.

Pump unit start

The pump unit is started by the start signal from the hydraulically operated section valve (1). Once started, the pump unit
produces the full water pressure in pipe section(s) in question.

Valve cabinet reset

Hydraulically operated section valve (1) – closed
Manual release valve (3) – in automatic position
Electric motor driven directional valve (4) – closed
Shut-off valves (6) – open

Marioff Corporation Oy • Virnatie 3 / P.O.Box 86, FI-01301 Vantaa, Finland

Tel. +358 (0)9 870 851 • Fax +358 (0)9 8708 5399 • www.marioff.com

© Marioff Corporation Oy 2008.

 Technical Data Sheet TC9838

Assembly Body RA 715F-S00D25S10

HI-FOG ® Stock code C42075.1 23 Jan 2006

84 mm 36 mm
(3.3 in) (1.4 in)

60 mm
(2.4 in)
Tube, O.D. 25

29
(1.1 in)

Thread
M36x2

Thread
M18x1,5
Spray head shown as an
installation example only - not
included in C42075.1 supply

Installation example

General Body material Cast stainless steel (CF8M)

Mass 0,45 kg

Connection Thread for cutting ring connection DIN2353

Installation Location Ceiling or wall

Projection Pendent or horizontal

Marioff Corporation Oy, P.O. Box 86, Virnatie 3, FIN-01301 Vantaa, Finland,
tel +358 9 870 851, fax +358 9 8708 5399, e-mail [email protected], www.hi-fog.com
Marioff Corporation Oy reserves the right to revise and improve its products and recommended system configurations as it deems necessary without notification. The information contained herein
is intended to describe the state of HI-FOG products and system configurations at the time of its publication and may not reflect the product and/or system configurations at all times in the future.
 1 of 2

Technical Data Sheet

Specification for water in HI-FOG® systems
TECHNICAL DATA SHEET DOC0002101 REVISION C DATE OF ISSUE 20 Oct 2011

If the water requirements below cannot be reached, the water used for the HI-FOG® system may be treated,
as described below in Water treatment, to enhance the HI-FOG® system lifetime.

A. Water requirements
• Equivalent of a potable supply
• Colourless and odourless
• Non corrosive
• Chloride concentration < 50 ppm (= 50 mg/l)
• pH value 7.0 – 9.0
• Iron (Fe) and Manganese (Mn); sum < 0.3 mg/l
• No free chlorine
• The fill line is routed through a < 100 μm filter (normally supplied with the unit). Suspended solids to be
as low as possible.

B. Water recommendations
• Conductivity < 400 mS/cm
• Total hardness 1 – 3 mmol/l (5 – 16 °dH)
• Suspended solids, TSS < 10 mg/l
• Sulphate < 50 mg/l
• TOC < 2 mg/l (Total organic carbon)

If pH < 7.0 then alkalinity should be 1 – 4 mmol/l, pH shall never be below 6.5.

The amount of organic material shall be kept to a minimum. The biological and bacterial growth should be
regularly monitored.

Distilled, demineralised, de-ionised or reverse osmosis water should not be used without adjustment of the
alkalinity (or pH-value to ~8).

C. Water treatment
Fire suppression additives shall not be applied. The HI-FOG® system is not to be shock chlorinated.

Bacteriological growth

If bacteriological growth is found the water should be either changed through thorough flushing, or treated.
The treatment may not be corrosive. Chlorine dioxide treatment may be used. Vernagroup’s Purogene or
Sanogene are possible treatment alternatives. The manufacturer’s instructions and recommendations and
applicable authorities’ requirements are to be complied with.

Shock chlorinated water may be used only after ensuring that there is no free chlorine and the other
parameters are within the specification (note: chlorination increases chloride content).
 2 of 2
Specification for water in HI-FOG® systems

Corrosion

If the water is found corrosive an inhibitor may be used. The inhibitor may not contain nitrates or sulphates.
It is also to be ensured the inhibitor complies with applicable authorities’ health and other regulations.
Nalco’s Silazur 100 is a recommended alternative. Other inhibitors may also be used provided they are
suitable for the materials used and not dangerous to people if they are exposed to the water mist.

D. Other aspects
If sea water or other water not complying with the specifications has entered the system (for example, in an
emergency situation), the HI-FOG® system including all affected branch piping, is to be thoroughly flushed.
The use of an inhibitor should be considered.

Marioff Corporation Oy • Virnatie 3, 01300 Vantaa, Finland • Tel. +358 10 6880 000 • Fax +358 10 6880 399 • www.marioff.com

© Marioff Corporation 2011. Marioff reserves the right to revise and improve its products and recommended system configurations as it deems necessary without notification.
The information contained herein is intended to describe the state of HI-FOG® products and system configurations at the time of its publication and may not reflect the product and/
or system configurations at all times in the future.
 Appendix D: Discussion of Fire Suppression Methods and Recent Data: Logic behind the
decision on the use of conventional water sprinkler systems in tunnels of the Alaskan Way Viaduct
(AWV) Project

This appendix summarizes the pros and cons of different fire suppression systems for tunnels and the
factors affecting the choice of systems in tunnels, along with the most recent test data. The studies carried
out in 2006 in support of the Alaskan Viaduct (AWV) project are discussed with regard to the choice of a
conventional sprinkler system. The major findings of large scale tests of mist systems, carried out since
the AWV studies, are then summarized.

The Alaskan Way Viaduct & Seawall Replacement Project

The Alaskan Way Viaduct and Seawall Replacement Project involved the construction of a new road
tunnel, the Waterfront Tunnel, and the retrofit of the existing Battery Street Tunnel. The Waterfront
tunnel is a 5300 ft (1615m) long double-deck bored tunnel; each road way in the Waterfront Tunnel is
designed for three lanes of traffic and is approximately 50 ft wide and 21 ft high. The Battery street
tunnel is an existing vehicle tunnel consisting of two-lanes of traffic and is approximately 2100 ft long
and 62 ft wide. Both tunnels will have fixed fire suppression systems. For the Battery Street Tunnel, a
complete replacement of the existing fire suppression system will be undertaken.

Transport of hazardous materials including flammable liquids and dangerous chemicals will be restricted
from the future AWV Tunnel by the Seattle Fire Code; therefore a bulk fuel tanker, and hence a large
pool fire, is not considered as the design standards.

In the studies carried out for the Seattle projects two types of fixed fire suppression systems including the
traditional sprinkler deluge system and high pressure water mist deluge system were considered. A fire
size considered of 100 MW was proposed, this being a typical value reflecting normal vehicle traffic
through a tunnel including cargo trucks but excluding bulk transport of flammable liquids.

For the tunnel tenability evaluation study, only 410 ft (120 m) long section of the proposed Waterfront
Tunnel with the similar cross section was modeled, as modeling a longer tunnel (5300 ft) would be
difficult because of the significant computational requirement. For the fire suppression and
extinguishment tests, a scale model of 90 ft long by 30 ft wide and 20 ft high is used. Simulations of both
shielded and unshielded fires were performed.

For the traditional sprinkler nozzles study, 800-1400 microns water droplet diameter and a water density
of 0.2 gpm/ft2 was used, and for the high pressure water mist system study, a 50 microns water droplet
diameter and a water density of 0.076 gpm/ft2. With the prescribed water flow rates and droplet diameter,
and the 100MW solid fuel fires, the simulation results were carried out for a section of tunnel 410 ft long.
These showed that:
 Temperature reduction resulting from the fire suppression was good with both the standard drop
sprinkler system and high-pressure mist system; both systems reduced the air temperatures to
manageable levels and prevented the spread of fire, but the large drop system was less effective at
reducing the air temperature.
 Visibility was improved upstream of the fire in the simulations. Downstream visibility was
reduced when suppression was activated. For some cases if the tunnel ceiling was low, there was
no stratification of smoke; the application of mist could improve the visibility.
  The high pressure mist system had the most significant reduction in thermal radiation. The
standard sprinkler systems also reduced the thermal radiation, allowing firefighters to get closer
to the fire.

In terms of the performance of fire suppression and extinguishment, the simulations showed that for the
shielded solid fuel fires, roughly equal reductions in HRR with either system were possible. For
unshielded solid fuel fires, the simulations showed that dramatic reductions in HRR occurred with a
standard drop sprinkler. For the mist system, simulation showed that the reduction in HRR of unshielded
fires was not significantly better than that for shielded fires.

Based on these findings, a traditional standard sprinkler system was recommended for the Alaskan Way
tunnel. It was felt that both standard sprinkler systems and water mist systems were virtually equal in
most aspects of the criteria. Both systems have the same ability to reduce the HRR of shielded fires; the
standard system is superior for unshielded solid fuel fires. It was also believed that high pressure mist fire
suppression in tunnels was a new technology while standard sprinkler system has been commonly used in
tunnels (in Japan and Australia) for many years. Before switching to a more complex and unproven
technology, it was believed that a substantial benefit would have to be shown.

The comparative study for the Alaskan Way tunnels had several limitations which would affect the
accuracy and applicability of their findings:
 Due to significant computational requirement for modeling the existing 5300 ft long tunnel, the
study only modeled a 410ft long section of the tunnel for the tenability condition study and a
scaled model tunnel (90 ft long by 30 ft wide and 20 ft high) for the fire suppression model
simulations.
 The tenability conditions of the tunnels are influenced by the tunnel length and the ventilation, the
outcome of the tenability evaluation study may not entirely applicable to a 5300ft long tunnel.
Also, and the conclusions drawn from a scaled model for the fire suppression/extinguishment
simulations may also not be applicable for a 5300 ft long tunnel with different dimensions of
tunnel cross sections.
 Since transport of hazardous materials including flammable liquids and dangerous chemicals will
be restricted from the future AWV Tunnel, the fuel tanker fire has not been considered. Therefore
the findings of the study are not applicable to the tunnel fires involved fuel tankers.

At the time of this study (2006), no full-scale test programs had been carried out to compare the
traditional sprinkler and water mist system and very few tunnels had been installed with the water mist
system. In addition, the traditional sprinkler system is very effective for solid fuel fires. Therefore the
recommendation on the use of a traditional sprinkler system for the Alaskan Way tunnels was reasonable.

However, a drawback of traditional sprinkler systems effect on pool fires was identified in the Ofenegg
Tunnel petrol fire test in 1965. The action of the large droplets caused an increase in fire size due to the
disturbance of the fuel pool. In the Ofenegg petrol fire test, deflagration created by re-ignition caused
extensive damage to the test setup and the ventilation installation in the tunnel (see EJMT fire suppression
report, Jan 2011).

Full scale fire tests with the use of traditional sprinkler system for large truck fires (200MW) have been
performed in Europe and results will be available to the public in the near future. Based on the
experiments, for large truck fire, the water sprinkler system with high application rate can enhance life
safety of the tunnel but the system cannot give good protection for tunnel structure. With the low-
application flow rates (same as used as design specification in Japan), the system cannot prevent fire
spread from one HGV to another, which is one of the main requirements for a fixed fire suppression
system.
There are also more tunnels in Europe that have been installed with the water mist systems (see 
Appendix A) since the time of the AWV study. Some of these tunnels have been retrofitted with water 
mist systems and some of the tunnels equipped with mist systems to allow dangerous good passing 
through.  
 
Summary of Fire Tests Carried Out since the AWV Study

It is evident from the more recent tests carried out in Europe since the Alaskan Way Study that mist
systems had a substantial mitigating effect on the fires studied. Pool fires were of short duration, in the
order of a few minutes, and the high temperatures and high CO levels decrease significantly within
minutes after the system was activated. Solid fuel fires took much longer to extinguish, in particular the
200 MW pallet fire, the conditions downstream remained untenable for the duration of the fire.
No special negative effects of the water mist system were observed beside the reduced visibility
downstream of the fire during operation. The relative humidity in the tunnel downwind of the fire arises
as an effect of activating the water mist system. The negative effect of higher humidity is small compared
to the direct positive effect of suppressing the fire.

Early detection and a quick response of the suppression system should be incorporated in the future
designs of the suppression system in tunnels.

Mist systems are more affected by ventilation. In the SOLIT tests the droplet sizes were significantly less
than 1 mm in diameter, the smallest were produced by the high pressure system. It is advantageous to
discharge the system upstream of the fire and allow the droplets to be transported by the air flow into the
fire. Due to the critical effect of ventilation just before and during the activation of the suppression
system, detailed studies are necessary to identify ventilation system operating strategies.
It can be concluded that the suppression effectiveness of both low and high pressure water mist systems
are fairly equal. High pressure water mist uses less water and suppresses fires more in the gas phase by
cooling hot gases, while low pressure is more effective in cooling the fuel surfaces. The low pressure
systems achieve best results for the pool fires tested, while the high pressure systems achieved best results
for the wood pallets fires. The thermal exposure is significantly reduced by both systems for the fires
tested.

All the tests with a HRR larger than 10 MW result in a significant back layering within the first minute
(before the activation of the suppression systems). By applying the suppression system, the capability of
the ventilation system to avoid back layering was significant, even at low ventilation rates. The
ventilation system and the water mist system were mutually mitigating the fire and the back layering
disappeared with minutes after activation of the water mist system.
From the above, it is concluded that a mist system is probably better for pool fires, though less effective
for solid fuel fires.
 Appendix E: Examples of water mist systems installed in road tunnels (UPDATED
DATA as of Jan 2012)

AQUASYS
 Mona Lisa tunnel (775 m, Austria, installed in 2004)
 Felbertauern tunnel ( at an altitude of 1632-1650m, exposed to temperatures of -30°C at cold
winter in Austria, 5034m long, high wind speed up to 1968 fpm ,i.e. 10m/s, system installed in
2006)
o (Note: the Felbertauerntunnel and the Mona Lisa Tunnel have both been existing tunnels
which have been retrofitted with water mist systems. )
 Roertunnel, NL, and Tunnel Swalmen, NL (A73, Roertunnel is 2.45 km long, longest road
tunnel in Netherlands; a sister tunnel , Tunnel Swalmen, 400 m long; both are new tunnels and
installed mist system in 2008)
o (Note: both tunnels are equipped with mist systems to allow dangerous goods passing
through)
 Gleinalmtunnel Austria (selected areas only)
 Öresund Tunnel DK-SE (service gallery only)

FOGTEC
 Virgolo tunnel (887m, dual lane, main link through the Alps from Italy through Austria to
Germany, especially for cargo transport, 30% traffic is Heavy Good Vehicles, Italy)
 Critical sections of M30 Tunnels, Madrid (2006, Spain)
 Silver Forest Tunnel ( Moscow, Russia, 2.1km, 2006)
o (The tunnel design comprises two parallel tubes, each measuring 2.1km long with a
diameter of 14.2m and double-deck construction)
 New Tyne Crossing (Newcastle, UK, 2009)
o (Two under-river tunnels are the vital part of the Tyne and Wear road network)
 Dartford crossing (M25, London K, 2 tunnels, 1.43 km, 2010)
 Train tunnel projects (metro Budapest, Hungary)
 Eurotunnel (channel tunnel), France/UK
 Cable tunnels in various countries

HI-FOG
 2 x NDIA Taxiway tunnels (road tunnels, 2x340m), 2009-2010, Qatar
 Helsinki Service Tunnel (road tunnels, 850m; 2000m) 2009-2010 Finland
 A86 Duplex Tunnel in Paris (road tunnels) 2005-2009
Appendix F Connections
 Appendix G: Answers to April 2012 CDOT Questions

Questions From CDOT April 2012 Responses from Consultant
1 Given the standards in  Part 2.3.8, filtration and water  The need for a water treatment plant depends on the quality of the water 
quality standards, where would the water treatment  source. If potable water is available, no treatment is necessary.  FOGTEC 
facility be located and how would the existing water  suggested to make use of the existing water tank. Usage of the existing fire 
treatment plant and fire hydrant system be  hydrant system is presumably ruled by the local authorities and regulations. 
incorporated? Possible interactions and operations with WM system need to be clarified 
together with the local safety authorities. Naturally, if both systems will be used 
simultaneously, the adequate size of the water reservoir needs to be ensured.

2 Is the method of last resort in Part 2.3.6 of flooding the  The flooding approach is described in the report of "risk analysis study of 
waste water plant really an alternative at all?  The  Hazmat Trucks through EJMT", 2006. It may be worthwhile to design a by‐pass 
electrical shorting caused by flooding would likely shut  for the wastewater plant and direct drainage from the water mist or a major 
down the entire facility and would be an undesirable  spill to an external sedimentation pond.
scenario.
3 3. Do the power requirements of the pumps exceed  As described in section 2.3.4 of the design report (pump stations), the electrical 
power available in the 480v system?  If the 2400v  power requirement for the pump units are 460KW, 510KW, and 1080KW 
system is used, what engineering will be required to  depending on the system used.  If this power is not available in the 480V system, 
provide this as essential power? a transformer 2400v to 480V is more cost effective than using 2400V pumps. 
Both AQUASYS and FOGTEC suggested that the diesel powered pumps can be 
used. As the water mist pump systems only run  for emergency cases and a few 
times a year for maintenance purposes,  the environmental impact of the diesel 
pumps is minimal.
4 What requirements does the power consumption put 
on the Emergency Generators, existing and future? The electrical power supply for the water mist pumps shall be redundant. This 
can be accommodated by either redundant power supply with transfer switches 
or by an emergency generator providing the same power. May need to upgrade 
the emergency power system. Again Both AQUASYS and FOGTEC suggested that 
the diesel powered pumps can be used (see the reasoning in Q.3)
5 Is recessing the nozzles in the ceiling panels feasible to 
From AQUASYS: Due to the design of the nozzles (in‐line with the piping) tunnel 
accommodate tunnel wash?
wash is not hindered. Installation of the nozzles behind the ceiling panels 
requires headroom of at least 100mm and complicates installation.  From 
FOGTEC: The tunnel wash will not affact the nozzles; no protective cups for 
nozzles are necessary as the FOGTEC discharge holes are relatively large and will 
not be afftected by dirt.  From HIFOG: The designed open spray heads, which 
are connected to the pipes using special assembly body will tolerate normal 
washing operations (which removes also possible dirt from the surfaces of HI‐
FOG components). As an option, nozzles can also be covered with protective 
cups. The cups could provide additional protection during the washing and also 
protect the spray heads against external dirt and mechanical damage.

6 Water supply main pipe will be located in the supply 
side duct ceiling? Yes (for AQUASYS'S design)
7 Where would pumps and associated housing be  The pump house shall be heated to slightly above freezing point. The energy to 
located?  Pg.10 states pump house would be next to  accommodate this temperature is rather low especially if the pump house is 
the water reservoir (within 15 meters) at the west  underground or half underground.  (The pump house must have adequate 
portal and should be kept from freezing.  Is this  ventilation to maintain appropriate temperature and to prevent the formation 
feasible?  Is this an underground structure?  Has this  of excessive humidity; low pressure pipes between the water tank and pump 
been looked at in context (maintenance and operations  room can naturally be equipped with electrical heating trace cables with 
vs. avalanche path).  Is this electric?  Is diesel shown as  thermal isolation to protection them against freezing.  The construction of the 
a backup only?     pump room and its equipment are not included to the scope of WM suppliers.)

8 Are intermediate pumps required? No.
9 CDOT’s diversion water right is 0.03cfs.  With a 120,000  The water tank will not need 6 days to refill after a fire incident. If this is still 
gallon tank, it takes over 6 days to fill once it is drained.   unsatisfactory, either the water supply has to be upgraded or the tank has to be 
Do we need to account for this in the design?  refilled by water trucks. 

10 Is a new tank required per number 9 and number 1? Depends on answer to Q9
11 Are intermediate tanks required? Depends on answer to Q9
12 Where should tanks be located?  Is this certain?  The design will assume the existing water tank located at the west end of the tunnels.

13 Can we make sure entire report has SI units in addition  Imperial Units and SI units will be used.
to metric units?
 Appendix G: Answers to April 2012 CDOT Questions

Questions From CDOT April 2012 Responses from Consultant
14 Are maintenance and operation costs known? According to the PIARC 2008 (road tunnels: assessment of fixed fire fighting 
systems), the maintenance costs of the FFFS per year are estimated to represent 
around 1 to 2.5% of the installation costs.  From AQUASYS: we have a 
maintenance contract for the water mist system for a similar tunnel; yearly 
maintenance cost are app. € 30,000.  From FOGTEC, the yearly maintance cost is  
€30,000 to 50,000 in addtion to some spare parts; if remote valves are used, 
maintenace cost can be reduced significantly . From Hi‐fog: the maintenance 
cost consists of spare parts and maintenance work. Since the system is not 
constantly being used a number of consumable parts remain minor considering 
to the total investment being mostly the parts for the pump units. Based on HI‐
FOG experience with the other tunnel projects, the estimated annual costs 
would be approximately 0.5‐1,0% of the purchase price. There might be certain 
local maintenance and service requirements, which could have an effect on the 
final maintenance scope and price. More detailed cost calculations need to be 
done later on based on final system configuration and requirements.

15 Is the existing drainage system adequate?  What   As indicated in design report (2.3.6 Drainage requirement), the maximum demand on 
improvements would be needed? the drainage capacity for a water mist system proposed for EJMT is in the range of 
126m3(33286 gallon) to 234m3 (61817 gallon) depending on the type of water mist 
system. The adequacy of the existing drainage system would need to be evaluated. 
Normally the drainage system shall have sufficient capacity to remove fire‐fighting 
water, storm water, tunnel wash water, carryover from the tunnel approach trench 
drains, vehicle drippings, and ground water infiltration from the roadway and tunnel. 
The travel lanes of the roadway shall not be used as a conveying system for water.

16 The wind that we could create in the air ducts if we  Yes. There are two issues here, one is the structual issue and the another is the heat 
have to run 600h.p. motors may affect the way they  transfer. As for the heat transfer issue, the design of the insulation and water 
design for support and also the way we heat the water  temperature maintained will consider the the high wind influence at the winter time 
“wind chill”‐ can this be factored in? during the fire incident. As for the wind load on the structural design of the water pipe 
support, that should be considered at the structural design stage.

17  We assume we need to have access to the water tanks  Whether we use the existing water tank or propose a new water tank, the tanks can be 
during winter months, making location a critical design  located at the west portal (the location for the existing water tank).
issue
APPENDIX H ‐ Portal Schematics
 EXISTING DRAW OFF
HOLDING TANK

0’ 50’ 100’ 200’

EXISTING DRAW OFF

LINE (APPROX) EXISTING CLEAN WATER
DISCHARGE TO CLEAR CREEK

NEW VANE GRATE INLETS

WITH 12" DIP (TYP)

CONNECTION TO EXISTING TUNNEL

DRAINAGE TANK AND DRAW OFF SYSTEM DISCHARGE TO CLEAR CREEK
ELEVATIONS, EQUIPMENT AND POINT OF TIE INTO EXISTING SYSTEM
CONNECTION TO BE DETERMINED
tcfg
.pl

VAULT AND VALVE ASSEMBLY

ty_V8i

CONTROL FLOW TO NEW SURGE

EXISTING TUNNEL DRAINAGE TANK OR DISCHARGE TO CLEAR CREEK

NEW 60,000 GAL
i
ghQual

STORAGE TANK
SURGE TANK
e:CDOT-PenTabl
Pen Tabl
Date:6/23/2012 g:CDOT-PDFHi
ot Confi
e.tbl Pl

Print Date: 6/23/2012 Sheet Revisions EJMT East Portal

Colorado Department of Transportation As Constructed Project No./Code
File Name:
647545_DES_Plan02.dgn Date: Comments Init. FFSS Drainage Modification
User:p0083853

No Revisions: 17810
Horiz. Scale: 1:100 Vert. Scale: Schematic Layout
Eisenhower Tunnel, West Portal P.O. Box 399
Dumont, CO 80436 Designer: Structure
Revised: C 0703-360
1700 Broadway Suite 900 Phone:303-512-5601 FAX:303-512-5675
Detailer: Numbers
parsons Denver, CO 80290
Region 1 GA Void:
Subset: Subset Sheets: of
Sheet Number 1
(303) 863-7900
 N=287
E=
16 69
72 9
53 4 .7
0. 97 EL
07
3 S
81
2
MP =111
73
56 3
F
21 67
M.P
62 86
.
1
G3P
0’ 100’ 200’ 400’

.6
S
G
WPeS
st
u
Wne
st
un

TE
MA
OXI
CLEAN EXISTING PIPELINE PR EXISTING PONDS
AP
5’ AND COLLECTION SYSTEM
44

NEW FILTRATION SYSTEM

UPSTREAM OF EXISTING STORAGE TANK
1
159’APPROXI
MATE INCLUDES NEW SHED OR VAULT
TO BE DETERMINED WITH COOPERATION
BY FOREST SERVICE

NEW CONNECTION TO EXISTING WATER

CLEAN EXISTING 120,000 GAL TANK
LINE AND PUMP STATION FOR FFSS
SYSTEM CONTAINED WITHIN PORTAL
tcfg

BUILDING OR NEW STRUCTURE AS REQUIRED

e:CDOT-PenTabl
Pen Tabl
Date:6/23/2012 ot Confi
e.tbl Pl i
ghQual
g:CDOT-PDFHi .pl
ty_V8i

Print Date: 6/23/2012 Sheet Revisions EJMT West Portal

As Constructed Project No./Code
Colorado Department of Transportation
File Name: 647545_DES_Plan01.dgn Date: Comments Init. FFSS Supply System
User:p0083853

No Revisions: 17810
Horiz. Scale: 1:200 Vert. Scale:
Eisenhower Tunnel, West Portal P.O. Box 399
Dumont, CO 80436 Designer: Structure
Revised: C 0703-360
1700 Broadway Suite 900 Phone:303-512-5601 FAX:303-512-5675
Detailer: Numbers
parsons Denver, CO 80290
Region 1 GA Void:
Subset: Subset Sheets: of
Sheet Number 2
(303) 863-7900
APPENDIX I
Estimate Summary for EJMT FFSS  at 10 % design level‐06/27/12
ITEM COST
Hi‐FOG estimate (Highest of three systems, use) $          
FOG‐TECH estimate $         
AQUA SYS estimate $         
East Portal‐tank and drainage for effluent $                 see spreadsheet
West Portal‐water filtration system $                 see spreadsheet
pumps (included in contingency) n/a
control systems (Included in contingency) n/a
Linear heat detectors $                 see spreadsheet
generators $                 see document

subtotal $          

Contingency @ 25% $             

Subtotal $          

CE and  indirects @ 20% $             

Total  $          
 East Portal EJMT‐Tank and Drainage for Effluent
Item # Description Price Quantity Units Cost

206 Structure Excavation

206 Structural Backfill (Class 1)

515 Waterproof Coating

601 Concrete Class D

602 Reinforcing Steel

603 8" Ductile Iron Pipe

603 24 Inch RCP (CIP)

604 Vane Grate Inlet (Double)(5 Foot)

Total
 West Portal-EJMT Water Filtration Costs
May 2012 Cost Estimate
ITEM
UNIT QTY Unit Cost Total
1 Mechanical Filtration Equipment
Automatic duplex strainer (2 units) based on the following: $        
304 Stainless steel interior and exterior
Design pressure 1200 psi @ 100 deg. F
ASME code Sec. VIII Div. 1
8" 600# Flanged inlet & outlet
designed to accept 1000 gpm water with a pressure drop of 2 psi
motorized scraper assembly 460v/3 ph/60 hz 1/2 hp TEFC motor
150 micron slot wedgewire SS316L screen
NEMA 4X FRP control panel
Installation upstream of existing tank

Piping tie‐in, pipe installation (8" diameter), pressure gauges, 
2
electrically actuated butterfly valves (3)            
3 Subcontractors
Electrical/Instrumentation Subcontractor Cost          
Coating/Painting Subcontractor Cost            
Filtration vault            
Insulation/Heat Tracing Subcontractor Cost            
SUBTOTAL
Contractor Overhead & Mark‐Up          
Taxes, Bonds & Insurance          
TOTAL ESTIMATED CONSTRUCTION COST (2012 DOLLARS):
     

Clarifications:
Assumed that existing water source is sufficient and can be utilized
Estimate based on the assumption that the existing water line at the point of tie‐in is 8" diameter
New Pumps are not included for the existing water source (assumed that they are not needed)
New Tanks are not included (assumed that existing tank is sufficient)
Assumed that the existing electrical power source is sufficient
Normal access to installation site is assumed
 Linear Heat Detectors
Project No. ESTIMATE NO:
LOCATION: SHEET NO: 1
ARCHITECT / ENGINEER HATCH MOTT MACDONALD DATE: Revised:
SUMMARY BY: PRICES BY: Protectowire/Sanders CHECKED BY:
UNIT TOTAL TOTAL TOTAL
MATERIAL TOTAL MATERIAL LABOR EQUIPMENT
ITEM DESCRIPTION QUANTITY UNIT LABOR LABOR LABOR DIRECT Comment
UNIT PRICE COST RATE COST
HOURS HOURS COST COST

1 Linear heat detection cable Protectowire Vendor qoute

2 Boxes for end of line resistors Vendor qoute

3 Zone boxes Vendor qoute

4 Fire panel with alarm point location meter Estimated

5 Fastener clips
Power feed to new panel XHHW-2
6 #16AWG

7 GRS Conduit 3/4"

8 Testing and commissioning

SUB TOTAL

Contingency factor for design phase

Bonds & insurances
Overhead & profit

TOTAL
Cost of Diesel Generators
FROM Norm Rhodes; 5/17/12 email

AQUASYS system (electrical power requirement for the water mist pump units is

Fogtec system (electrical power requirement for the water mist pump units is

Hi-fog system (electrical power requirement for the water mist pump units is : assume
diesel-engine-generator at which costs )