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Automatic Fire Suppression System for Oil and Gas Blowouts

On October 11–12, 2021, the Orenburg branch of the Federal State Budgetary Institution All-Russian Research Institute for Fire Protection (FGU VNIIPO) under EMERCOM of Russia hosted the scientific and practical conference "Safety in the Oil, Gas, and Transport Industries - 2021." At the testing and training grounds, advanced fire protection tools and technologies for the oil and gas industry were demonstrated. A prototype of an automatic fire suppression system for oil and gas blowouts was showcased, mounted on an automotive chassis. This system is capable of extinguishing blowouts with a flow rate of up to 5,000 cubic meters per day from a distance of 15–20 meters. The suppression process employs a high-speed powder-gas jet to deliver the extinguishing agent directly to the base of the burning blowout. This creates a fire-extinguishing concentration in the combustion zone while the jet’s velocity detaches the flame from the base of the blowout. This ensures effective fire suppression in under 10 seconds from the start of the powder-gas extinguishing agent deployment.

Oil and Gas Blowout Fire Suppression Test

On December 26, 2019, a successful Fire Extinguishing test was conducted at the test site of LLC "Kalancha" using the BiZone Automatic Powder-Gas Fire-Extinguishing System (APGFSS).

The test demonstrated the system’s efficiency as the oil and gas blowout fire was effectively extinguished.

Fire Protection of Oil Heating Furnaces with the "BiZone" powder-gas Fire Extinguishing System

On August 23, 2018, full-scale live fire tests of the BiZone powder-gas Fire Extinguishing System, model МГПП-110-СО2-30-РХ-АВСЕ-У2, were conducted in the Republic of Kazakhstan. The objective was to evaluate its effectiveness in extinguishing flammable liquids in PTB-10 oil heating furnaces (thermal capacity: 5.5–11.6 MW, internal tubular furnace volume: 120 m³) used in oil refining and extraction facilities.

The tests were carried out at the UPSV-2 Preliminary Water Discharge Unit, part of JSC "Ozenmunaigas", located in Zhanaozen.

Test Procedure: The test commenced with the furnace being activated in operational mode. The time elapsed from the start of diesel fuel delivery (300 liters at a flow rate of 1.6 kg/s) to the point at which the critical threshold for exhaust gas temperature (not exceeding 650°C) was reached was 105 seconds.

The manual activation of the powder-gas Fire-Extinguishing Module МГПП-110-СО2-30-РХ-АВСЕ-У2 was conducted.

The discharge duration of the powder-gas extinguishing agent, sufficient to achieve the required extinguishing concentration within the tubular furnace, was 8 seconds, aligning with the specifications in the technical documentation (PS 4854-009-13393076-2005, maximum of 10 seconds).

The fire extinguishing time for the tubular furnace was 12 seconds, also meeting the requirements of the technical documentation (PS 4854-009-13393076-2005, maximum of 15 seconds).

After the suppression process, the furnace’s internal volume was purged using a stationary fan.

Diesel fuel delivery to the industrial burner continued uninterrupted for 15 minutes after fire suppression. No re-ignition occurred during this time.

The extinguishing agent introduced into the tubular furnace did not cause any damage to the equipment or structural components of the furnace.

Conclusion: The BiZone automatic powder-gas fire-extinguishing system (APGFSS), equipped with the МГПП-110 module, is effective and suitable for extinguishing fires in PTB-10 type oil heating furnaces.

Fire Tamers from Sergiev Posad

Full-Scale Testing of the "BiZone" Fire Suppression System with Rosneft: Extinguishing a 2,000 m³ RVS Tank

In August 2014, full-scale tests of the "BiZone" powder-gas Fire Extinguishing System were conducted at the test site of LLC "Kalancha" in collaboration with Rosneft. The experiment focused on extinguishing a fire in a 2,000 m³ RVS (Vertical Steel Tank). Testing was performed on a mock-up of an RVS-2000 tank, measuring 15 meters in diameter and 3 meters in height, with a simulated fire involving 181 m² of burning AI-98 gasoline.

The fire was extinguished using the "BiZone" APGFSS-2000 automatic powder-gas fire-extinguishing system, equipped with BiZone МГПП-110 powder-gas modules. The system featured primary and backup arrays mounted on a unified foundation to deliver a powder-gas mixture into the tank.

Upon detecting the fire, sensors installed along the upper rim of the tank triggered the fire alarm and control panel, which sent an activation signal. Thanks to the system’s low inertia, the delivery of the powder-gas extinguishing mixture into the protected volume began within 25–30 seconds after ignition. The extinguishing agent delivery time ranged from 10 to 15 seconds.

For floating roof tanks, fire suppression is performed volumetrically by filling the entire space above the floating roof, accounting for the minimum product level.

The extinguishing agent is dispersed parallel to the surface of the petroleum product, creating a continuous powder-gas blanket. This blanket isolates the flames from the fuel surface, blocks heat transfer from the flames to the fuel, restricts oxygen access, cools the fuel surface, and extinguishes the fire within its effective range.

The test results led to recommendations for updating Rosneft’s internal regulatory documents. These changes would enable the use of "BiZone" Powder-Gas Fire Extinguishing Systems, equipped with MGPP modules, for extinguishing vertical steel tanks with capacities of up to 20,000 m³.

Protection of High-Rack Storage Facilities with "BiZone" Modules

On October 10, 2013, a series of Fire Extinguishing tests were conducted at the VNIIPO EMERCOM test site in the Orenburg region. These tests demonstrated the effectiveness of "BiZone" МГПП-110-СО2-1-3-У2 powder-gas Fire-Extinguishing Modules for extinguishing fires in high-rack storage facilities.

The "BiZone" powder-gas Fire Extinguishing technology, developed by NPO "Kalancha", represents a cutting-edge approach to Fire Extinguishing. This system utilizes a combination of extinguishing powder and gas to directly target fire sources. Thanks to the unique characteristics of the powder-gas extinguishing agent and its delivery method, BiZone modules are highly effective for localized volumetric fire extinguishing.

The extinguishing powder is transported by a gas mixture, which uniformly fills the protected space, ensuring adequate concentration for fire suppression even in hard-to-reach areas or shadow zones. The gas mixture serves a dual purpose: it propels the powder from the module and actively contributes to fire suppression by inerting and cooling the protected volume.

Fire sources were placed on the floor and on racks at heights of 4 and 8 meters. Following suppression, no signs of combustion or smoldering were detected. The BiZone modules successfully passed all tests and were officially recommended for protecting high-rack storage facilities.

Protection of Open Outdoor Installations in the Oil and Gas Sector Using "BiZone" Modules

On October 10, 2013, a series of successful tests were conducted at the VNIIPO EMERCOM test site in the Orenburg region to assess the performance of "BiZone" powder-gas Fire Extinguishing equipment for protecting open outdoor installations in the oil and gas sector. The tests were carried out using "BiZone" МГПП-110-СО2-1-3-У2 powder-gas fire-extinguishing modules.

NPO "Kalancha" has developed and patented an advanced fire suppression method that employs a mixture of extinguishing powder and gas to directly combat fire sources. Experimental data shows that achieving fire suppression for flammable liquids requires creating the necessary extinguishing concentration at the ignition point for just 2–3 seconds. The "BiZone" module delivers its extinguishing agent within 8–10 seconds, significantly exceeding the minimum time needed for effective suppression by a factor of 3–4. Additionally, the powder-gas agent is discharged at a velocity of up to 70 meters per second, ensuring it remains effective even in windy conditions.

The "BiZone" Automatic powder-gas Fire Extinguishing Systems have demonstrated their effectiveness by successfully extinguishing a fire within the bunded area of an outdoor installation.

Demonstration of the Mobile System "Gyurza"

The "Gyurza" Mobile Hydro-Abrasive Cutting and Fire Extinguishing System is a cutting-edge solution designed for firefighting and emergency rescue operations. This innovative domestic development employs advanced techniques to combat fires effectively.

The system utilizes a high-pressure mixture of water and abrasive to instantly cut through all known construction and structural materials without requiring entry into the building. After creating an opening, fire suppression is carried out using finely atomized water or water mixed with a foaming agent delivered through the newly created access point.

Fire Suppression for Outdoor Installations

Tests were conducted to extinguish model fire sources 2B, D = 290 mm, fueled by AI-80 gasoline, located outdoors at a distance of 20 meters from the МПП-100 "BiZone" module. The results confirmed the efficiency of "BiZone" combined powder-gas Fire-Extinguishing Modules for protecting outdoor installations.

Fire Suppression Testing for Open Railcar Loading/Unloading Racks

In August 2012, successful fire suppression tests (two attempts with a 100% success rate) were conducted at the VNIIPO test site on an open railcar loading/unloading rack. The test simulated a fire near the tank car manway and the spill of burning petroleum products. Despite wind speeds exceeding 20 m/s, the suppression was highly effective. The flammable liquid used was stabilized gas condensate, known for its intense combustion during the initial stages of a fire.

Efficient Protection of Gas Stations with "BiZone" Modules

In May 2012, Fire Extinguishing tests were conducted at a gas station. As specified in the technical requirements, two fire suppression zones were identified: the fuel drainage pit for underground storage tanks and the localized area surrounding the fuel dispensers. The tests used "BiZone" МПП-8 powder-gas Fire-Extinguishing Modules in explosion-proof configurations, specifically designed for outdoor use in a temperature range of -50°C to +50°C.

The "BiZone" powder-gas Fire Extinguishing technology efficiently extinguishes fires during their initial stages by rapidly delivering a mixture of extinguishing powder and gas to the fire zone. Due to its unique properties, the technology ensures effective suppression even in hard-to-reach areas.

To extinguish fires in the fuel drainage pit connected to underground storage tanks, a single "BiZone" МПП-8 Fire-Extinguishing Module was deployed, positioned at a distance of 3 meters. The extinguishing agent was delivered via a pipeline, which can be extended up to 12 meters if required.

On the platform surrounding the fuel dispensers, eight fire sources containing gasoline (each with a diameter of 290 mm) were arranged. After 30 seconds of burning, the Fire Extinguishing system was manually activated. Following the activation of the modules and the dispersion of the extinguishing agent, all fire sources were extinguished successfully. Based on the results of these tests, a decision was made to equip gas stations with the "BiZone" powder-gas Fire Extinguishing system.

Ammunition Depot Fire Suppression

On September 8, 2006, tests were conducted to evaluate the effectiveness of an automatic Fire Extinguishing system based on a powder-gas Fire-Extinguishing Module. The objective was to assess its performance in extinguishing fires in ammunition storage compartments and its feasibility for use in arsenals, military bases, and depots. The tests were conducted at a military unit within a newly constructed reinforced concrete storage facility measuring 200 m² with a volume of 1,200 m³. The experiment included two stacks of wooden ammunition crates for 100 mm ammunition, each measuring 3.5 x 15 meters and stacked to a height of 3.5 meters on T2-type wooden supports.

The "BiZone" powder-gas Fire-Extinguishing Modules proved highly effective and were recommended as the primary component for automatic Fire Extinguishing systems in ammunition depots.

Fire Suppression Test for Compressed Natural Gas Leak

December 2011: A fire suppression test was conducted to evaluate the extinguishing effectiveness for a simulated compressed natural gas leak. The gas was continuously supplied through a hose, and suppression was carried out using the "BiZone" МПП-(Н)-8-Кд-1-БСГ-УХЛ3.1 Fire-Extinguishing Module, designed for explosion-proof operation and suitable for temperatures ranging from -50°C to +50°C.

Extinguishing a Full-Scale (1:1) Model of a Vertical Steel Tank (VST-20000) Using the powder-gas Fire Extinguishing System "BIZONE" UGPP-20000

In September 2011, a full-scale (1:1) model of the VST-20000 tank was successfully extinguished using the "BiZone" UGPP-20000 powder-gas fire extinguishing system. Key specifications: Diameter – 40 meters, Area – 1,250 m², fuel type – AI-80 gasoline.

Extinguishing a VST-5000 Tank Using the powder-gas Fire Extinguishing System "BIZONE"UGPP-5000

On August 11, 2010, at a testing ground in Orenburg, "Kalancha" conducted the world’s first trials of the UGPP-5000 automatic powder-gas fire extinguishing system. For the test, a water-filled tank with a volume of 5,000 m³ was used. Approximately 10 tons of gasoline were poured into the tank, forming a fuel spill layer 3 centimeters thick. The extinguishing agents used included 800 kg of extinguishing powder and 300 kg of carbon dioxide, totaling 1,100 kg. The fire was extinguished in just 10 seconds.

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