Nitrogen Injection Fire Protection System (NIFPS)_Installation & Testing Procedure
1. PURPOSE
To provide fire protection by automatically injecting high-pressure nitrogen gas into the
transformer conservator during abnormal overpressure or fire condition, displacing oxygen and
extinguishing fire.
2. SYSTEM COMPONENTS
Mechanical Components
• Nitrogen gas cylinder (200 bar)
• High-pressure flexible hose / SS pipe
• Solenoid valve (electrically operated)
• Non-return valve (NRV)
• Conservator inlet fitting
• Manual release lever/button
• Wall-mounted or cabinet enclosure for cylinder
• Pressure gauge
• Cylinder support frame/clamp
Electrical Components
• Local control panel
• PRD signal terminal or fire detector interface
• Pressure switch
• Solenoid valve actuator wiring
• Manual/Remote discharge button
• Status indication lights (Ready, Discharge, Low Pressure)
• SCADA/Trip relay interface (optional)
3. MECHANICAL INSTALLATION PROCEDURE
Step-by-Step
a. Cylinder Mounting
• Position the nitrogen cylinder vertically in a weatherproof steel cabinet near the
transformer.
• Use secure cylinder clamps with vibration isolators.
• Ensure cabinet has ventilation and is lockable.
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Nitrogen Injection Fire Protection System (NIFPS)_Installation & Testing Procedure
• Provide foundation bolts or anchor fasteners if installed on concrete base.
b. Piping Installation
• Use high-pressure SS 304/316 tubing or copper-nickel alloy pipes.
• Connect cylinder outlet to transformer conservator with:
o Solenoid valve mounted inline.
o Non-return valve (NRV) before conservator entry.
• Pipe should be:
o Free from bends < 5D radius
o Firmly clamped every 50–60 cm
o Laid avoiding any stress or sharp directional change
• Ensure proper union fittings at all threaded ends.
c. Conservator Connection
• Drill and tap connection into conservator with isolation valve and threaded coupling (as
per OEM layout).
• Apply sealant (e.g., PTFE tape) and torque fittings per specification.
d. Labels & Signage
• Fix safety signage: “NITROGEN FIRE PROTECTION INSTALLED – DO NOT
BLOCK OR OBSTRUCT.”
• Indicate direction of nitrogen flow and panel ID.
4. ELECTRICAL INSTALLATION PROCEDURE
Step-by-Step
a. Control Panel Mounting
• Install control panel on a wall/pedestal near the cylinder cabinet or in transformer kiosk.
• Ensure rain hood, proper IP rating (IP55/IP65), and accessible height (1.2–1.5 m).
b. Wiring Connections
• Connect 24V DC (or 230V AC, as per design) supply to panel.
• Wire the following:
o Solenoid valve actuator output
o Pressure switch from cylinder
o PRD trigger (normally open contact or dry loop)
o Manual pushbutton connection
o SCADA / Alarm panel interface
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Nitrogen Injection Fire Protection System (NIFPS)_Installation & Testing Procedure
c. Grounding
• Properly earth the control panel body and solenoid using 8 SWG GI wire or Cu strip.
• Ensure continuity with main transformer earthing grid.
d. Cable Management
• Route control cables in armoured conduits.
• Use ferrules, crimp lugs, and proper termination at all ends.
• Label all wires as per schematic.
e. Testing Points
• Install test switch and LED indications for:
o Power ON
o System Ready
o Discharge Activated
o Cylinder Low Pressure
5. PRE-COMMISSIONING CHECKS
Checkpoint Method Acceptance Criteria
Cylinder Pressure Visual – Pressure Gauge ≥ 90% of rated (typically 180–200 bar)
Mechanical Fixing Manual inspection All fittings tight, clamps secure
Pipe Leak Test Soap solution test No bubbles, hissing, or pressure drop
Solenoid Valve Activation Simulated signal Audible/visual actuation
PRD Interface Simulate trigger System discharges (dry run)
Manual Push Button Press test System responds
Alarm & SCADA Signals Simulate activation Signals received remotely
6. POST-INSTALLATION DOCUMENTATION
• As-built drawing of system layout
• Cylinder serial number, pressure, and test certificates
• Control panel wiring diagram
• Pressure switch setting report
• Checklist signed by contractor, engineer-in-charge, and OEM (if applicable)
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Nitrogen Injection Fire Protection System (NIFPS)_Installation & Testing Procedure
7. MAINTENANCE INSTRUCTION
Frequency Task
Monthly Cylinder pressure verification
Quarterly Pipe fittings inspection & leak test
Half-Yearly Solenoid & manual discharge test
Annually Control panel relay test, alarm output
Optional Additions:
• Flame detectors/IR sensors for automatic PRD bypass
• Trip interlock to transformer breaker
• SMS/Cloud-based alarm notification
8. Testing & Commissioning Procedure
1. Visual & Mechanical Inspection
Objective: To ensure proper installation and physical condition of all components.
Procedure:
• Inspect nitrogen cylinder placement (vertical, secured, no corrosion).
• Check discharge piping from cylinder to conservator:
o Must be rigid (SS/Brass), without sharp bends or leaks.
o All fittings should be tight and clean.
• Verify solenoid valve and manual actuator are installed per schematic.
• Confirm nameplate, warning signs, and instructions are displayed.
Acceptance Criteria:
• All components match the approved drawing and BOM.
• No visible mechanical damage or corrosion.
2. Cylinder Pressure Check
Objective: To confirm that the nitrogen cylinder is adequately charged.
Procedure:
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Nitrogen Injection Fire Protection System (NIFPS)_Installation & Testing Procedure
• Read pressure from cylinder gauge.
• Record pressure and temperature (to correct for ambient variation).
• Compare with standard filling pressure (typically 150–200 bar at 27°C).
Acceptance Criteria:
• Cylinder pressure ≥ 90% of rated value.
• No sudden drops or leakage signs.
3. Piping Leak Test
Objective: To detect leaks in the discharge piping system.
Procedure:
• Apply soap solution at all joints and valve interfaces.
• Slowly open isolation valve (do not open to transformer).
• Check for bubble formation or hissing noise.
Acceptance Criteria:
• No bubble formation at joints.
• No audible leaks.
4. Solenoid Activation Test (Dry Run)
Objective: To verify the actuation of the solenoid-operated valve on control signal.
Procedure:
• Deactivate cylinder (close valve or use test cylinder).
• Send a 24V DC signal from the control panel or test switch.
• Confirm:
o Solenoid valve clicks (audible/visual confirmation).
o Control panel shows “Actuation/Discharge” status.
Acceptance Criteria:
• Valve actuates promptly on signal.
• Panel and annunciation respond properly.
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Nitrogen Injection Fire Protection System (NIFPS)_Installation & Testing Procedure
5. Manual Discharge Test (Simulated)
Objective: To verify the function of the manual release mechanism.
Procedure:
• Engage manual pushbutton release from panel.
• Confirm:
o Solenoid gets signal.
o Alarm and discharge indicators turn on.
o Remote alarm (SCADA, if applicable) receives status.
Acceptance Criteria:
• Manual actuation works correctly.
• All alarms activate simultaneously.
6. Functional Simulation via PRD Trigger (if integrated)
Objective: To test if the system auto-activates in response to pressure rise or heat event.
Procedure:
• Simulate PRD contact closure.
• Observe system for:
o Auto actuation of solenoid valve.
o Alarms and indicators activating.
o SCADA relay triggering (if configured).
Acceptance Criteria:
• Auto activation upon PRD contact is successful.
• All communication and safety links perform as expected.
7. SCADA / Remote Interface Test
Objective: To confirm signal transmission and feedback to SCADA or protection systems.
Procedure:
• Trigger test signal from panel.
• Verify signal receipt on SCADA (e.g., Binary Inputs).
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Nitrogen Injection Fire Protection System (NIFPS)_Installation & Testing Procedure
• Observe update of “Ready,” “Alarm,” and “Discharged” status.
Acceptance Criteria:
• Signal reaches SCADA or remote panel without delay.
• All statuses are clearly transmitted and acknowledged.
Summary Table
Task Method/Details Acceptance Criteria
Cylinder Mounting In cabinet, upright Firm & accessible
Pipe Routing Leak-proof metal pipe No bends or obstructions
Pressure Test Cylinder pressure reading 150–200 bar
Leak Test Soap solution on joints No air/gas leaks
Functional Test Simulate PRD/fire signal Valve actuates
SCADA Interface Alarm/trip status Signal reflected properly
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