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Engine Test Cells

Shanghai, Partner seminar October 7th 2014

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Some topics

• What has been Fire Tested for Engine Test Cells application?

• System design

• Certificates and Design Manual

• Typical Design

• Explanation of Components

High Pressure Water Mist in Engine Test Cells

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• Option 1

– Tested in Cologne in 2006 according to prEN DIN 14972: Oct. 2004 – appendix A.3 (Protection of Engine Test Benches (Motor test Cells))

– 80 bar system.

– Fire tests witnessed by TFIS and nozzles component tested by DNV.

• Option 2

– Tested in Magdeburg, May 2012 according to FM 5560 – appendix E (Fire Tests for Water Mist for the protection of Machinery Spaces)

– 60 bar system.

– Fire tests witnessed by VdS and nozzles component tested by FM.

2 options can be selected:

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– appendix A.3 (Protection of Engine Test Benches (Motor test Cells)

• Enclosure L=6m x W=4m x H=5m ~ 120 m3 room volume

• 80 bar system

• 2 local application open nozzle heads, type 7-01-56-5-12-00 positioned in

the ceiling, (water discharge per nozzle head: 10,6 l/min)

• 2 laterally positioned nozzle lances, each with 5 individual micro nozzles of

type 1927 (water discharge per nozzle lance: 15 l/min)

• Totally usage of water in the test; 51,2 l/min in 120 m3, corresponding to

0,43 l/min/m3

Option 1: In Cologne 2006

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Nozzle Head Data Sheets for the nozzles used in 120 m3 Engine Test Cell fire test-Option 1

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Nozzles above

Typical design

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Nozzles from the side

Micro nozzles in sub-floor

Typical design

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Typical design – pipe route

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• Enclosure L=10m x W=10m x H=5m ~ 500 m3 room volume

• 60 bar system

• 9 open nozzle heads, type BR positioned evenly spaced throughout the

ceiling, (water discharge per nozzle head: 14,4 l/min)

• Totally usage of water in the test; 129,6 l/min in 500 m3, corresponding to

0,26 l/min/m3

• Additional nozzles may be installed in strategic positions to cover high fire

hazards

Option 2: In Magdeburg, May 2012: VdS acc. to FM5560

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VdS acc. to FM5560 – appendix E (Fire Tests for Water Mist for the protection of Machinery Spaces)

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VdS 500 m3 Machinery Space Test Certificate and Design Manual

See manual

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VdS 500 m3 Machinery Space BR Nozzle Head option 2

View BR nozzle data sheet

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Refer to Design Manual, Chapter 4

• Notice;

• Are the enclosures within what has been tested; 500m3 and ceiling height less than 5 meters

• How many sections (Engine Test Cell Enclosures) needs to release

simultaneously – determining the pump and pipe capacity/dimension

• Ceiling mounted nozzles shall be located in an even pattern, additional

nozzles can be located in strategic locations in the Engine Test Cells, where

the fire hazards are found; around engines, fuel lines and other hot spots

• Take high notice of obstructions to nozzles

System Design

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Things to notice, continued…

• Any sub-floors where fuel spill can occur, needs also attention

• Protection of ducts wherein fire could spread

• When designing, always meet the required volumetric density (Litre/minutes/m3)

System Design

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Section Valve assemblies – open nozzle section valve

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Section Valve assemblies – open nozzle section valve

Things to notice

• Solenoid Valve pilot

operated 24VDC / 230 VAC

• Manual override possibility

• Up to 150 l/min

• Isolation valves are

typically monitored for

open/close position

• Needs a pre-pressure of

~10 bar to avoid leaks

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Example of a SEM-SAFE® Pump Unit

Things to notice

• 2 PAH80 pumps

• 2 x 30 kW

• 224 l/min – 130 bar

• Available with soft

start and other

features

• Compact

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Design Recommendations Engine Test Cells

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To be noted (important)

• Open nozzle system with strategic placed micro nozzles

• Machines, Fuel Lines, Ventilation and other associated processes must be

shut down during release of the water mist system

• Max ventilation opening ~4 m2 (VdS)

• Discharge time 45 minutes (acc. VdS), however agreed with AHJ

• Fast acting detection system (Flame detection)

Summary Engine Test Cells

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References – engine test cells

• We have more references for Motor Test Cell protection with Daimler-

Chrysler, VW, BMWi, Bosch, BLB Aachen - all in Germany and

SNECMA (Jet fuel engines) in France

• There is however an issue here; these car producing companies have

all made restrictions to us and our German partners, that we are not

really allowed to make use of these references commercially

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• Our partner Tyco Total Walther in Germany have in the beginning of 2010 realized a project together with VW in Wolfsburg for “Halle 77” and received an order for a SEM-SAFE® Water Mist fire protection system for ~16 engine test cells. (recently Tyco Total Walther have received a further order for another 4 test cells – also to be supplied with water from the initial pump unit

• The system is made for VdS approval – both fire test and test of nozzle heads.

• A new fire test to FM5560 for 500m3 machinery spaces approved by VdS has quite recently been carried out by DS and Tyco Total Walther in joint venture.

High Pressure Water Mist in Engine Test Cells

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THANK YOU!